Results for “materials modelling” — Page 51

NASA NTRS2019

Verification Benchmarks and Validation of MAT261 for High Energy Dynamic Impact Applications

Advanced computational methods for composite structures can enable smarter testing and potentially certification by analysis. These methods, known as progressive damage and failure analysis (PDFA) methods, can predict lamina level mechanics including failure and subsequent propagation. When introduced into a commercial off the shelf finite element solver such as ABAQUS, LS-DYNA, or ANSYS, it enables end users to effectively exercise PDFA methods; however, it requires an understanding of the assumed mechanics and underlying coded response. In this paper, verification benchmarks developed under the NASA Advanced Composite Consortium for a class of PDFA methods known as continuum damage mechanics approaches are applied to the native LS-DYNA material model MAT261. As a result of the verification, an instability was discovered and subsequently corrected with an engineering solution. The results of the preliminary MAT261 simulations for high energy dynamic impact and the engineering solution are compared and a discussion about the significance is presented.

Molitor, Matthew↗

NASA NTRSDate not supplied

Application of the NASA Multiscale Analysis Tool: Multiscale Integration and Interoperability

The NASA Multiscale Analysis Tool (NASMAT) was developed recently to allow a wide variety of multiscale analysis problems to be effectively and efficiently solved. The architecture of NASMAT was established specifically to enable parallelized, “plug-and-play” functionality to reduce the complexity associated with adding new features to the code in the future and to allow end users to rapidly implement and evaluate user-defined capabilities. Additionally, the tool utilizes recursive data structures and subroutines to allow for an arbitrary number of length scales when performing multiscale analyses of heterogeneous materials. These features permit the rapid integration of user-defined capabilities (e.g., a material model, micromechanics approach, or failure theory) at all stages within a NASMAT calculation while leveraging built-in techniques where needed. Additionally, these features allow NASMAT to both be called from an external program as well as call an external program. This paper specifically focuses on the multiscale integration and interoperability of NASMAT with other analysis techniques through an illustrative, multiscale analysis of a 3D woven polymer matrix composite (PMC).

NASMAT↗

NASA NTRSDate not supplied

Multiscale Simulation of Deployable Composite Structures

In this paper, a multiscale simulation method for analyzing deployable composite structures is presented. Effective shell properties of the composites are obtained based on Mechanics of Structure Genome (MSG) homogenization, and then implemented into a user-subroutine UGENS for structural simulation with shell elements in Abaqus. The column bending test(CBT) of a flat thin flexure and lenticular composite boom in a simplified deployer structure are studied for demonstration. A viscoelastic material model with direct integration is adopted in this paper. The CBT simulation shows good agreement with experiments during relaxation, while errors are observed when comparing residual deformation. It is shown that this CBT model can be calibrated to CBT test results. For the lenticular boom analysis, the complete process of flattening, coiling, stowage, deployment and recovery is simulated with the viscoelastic shell model.

Finite element analysis↗

NASA NTRSDate not supplied

Scalability of Cohesive Fatigue Analyses Using Explicit Solvers

A cohesive fatigue law has been integrated into a constitutive material model compatible with an explicit finite element solver. The cohesive fatigue model response is based on engineering approximations of the endurance limit and the Goodman diagram. This approach can predict stress-life diagrams for crack initiation, the Paris law regime, and transient effects of crack initiation and stable tearing. Simplified cyclic loading is utilized so that the applied load(or displacement) corresponds to the peak load of a fatigue cycle. Loads are held constant during fatigue while damage develops with increasing solution increments. An automatically-calculated ratio of fatigue cycles per solution increment controls the rate of damage growth, ensuring that damage growth is modeled with a sufficient minimum number of increments and damage growth advances to a minimum desired extent within the explicit analysis step time. The compatibility with an explicit finite element solver enables the analysis of structures that are computationally intractable for implicit finite element solvers. Scalability studies are conducted for geometrically nonlinear problems involving fiber-reinforced composite structures that exhibit fatigue damage growth of interacting matrix cracks and delaminations

Frank A Leone↗

NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

Additive Manufacturing↗

NASA NTRS2021

Arecibo Observatory Auxiliary M4N Socket Termination Failure Investigation

The NASA Engineering and Safety Center (NESC) was requested to support the Arecibo Observatory failure investigation in determining the root cause of the Auxiliary M4N cable failure. The NESC and Kennedy Space Center led an integrated NASA investigation with support from Marshall Space Flight Center and The Aerospace Corporation that included forensic investigation of failed hardware, finite element modeling, materials characterization, and root cause analysis. This document contains the outcome of the NESC Assessment.

Zinc Spelter Sockets↗

NASA NTRSDate not supplied

A Comparison of Two Non-Contact Strain Measurement Techniques with Applications to Scientific Balloons

Strain measurements of scientific balloon films are necessary for evaluating the film’s material properties, validating material models, and structural evaluations of scale model balloons. This paper presents a comparison of the strain measurement techniques used by the Balloon Program Office’s Balloon Research and Development Lab at NASA Wallops Flight Facility. Two non-contact strain measurement techniques are presented for comparison, along with an assessment of measurement accuracy for both methods. The case study of a vertically oriented cylindrical balloon is presented to illustrate both systems’ performance and draw nominal conclusions of strain as a function of pressure and axial load.

Non-Contact↗

NASA NTRSDate not supplied

A Comparison of Two Non-Contact Strain Measurement Techniques with Applications to Scientific Balloons

Strain measurements of scientific balloon films are necessary for evaluating the film’s material properties, validating material models, and structural evaluations of scale model balloons. This paper presents a comparison of the strain measurement techniques used by the Balloon Program Office’s Balloon Research and Development Lab at NASA Wallops Flight Facility. Two non-contact strain measurement techniques are presented for comparison, along with an assessment of measurement accuracy for both methods. The case study of a vertically oriented cylindrical balloon is presented to illustrate both systems’ performance and draw nominal conclusions of strain as a function of pressure and axial load.

Non-Contact↗

NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗

NASA NTRS2023

Finite Element Simulation of Three Full-Scale Crash Tests for Cessna 172 Aircraft

The NASA Emergency Locator Transmitter Survivability and Reliability project was initiated in 2013 to assess the crash performance standards for the next generation of emergency locator transmitter (ELT) systems. Three Cessna 172 aircraft were acquired to perform crash testing at the NASA Langley Research Center Landing and Impact Research Facility. Full-scale crash tests were conducted in the summer of 2015 and each test article was subjected to severe, but survivable, impact conditions including a flare-to-stall during emergency landing, and two controlled-flight-into-terrain scenarios. Finite element analyses were performed to numerically simulate the aircraft response to the crash tests. The first test simulated impacting a concrete surface represented analytically by a rigid plane. Tests 2 and 3 simulated impacting a dirt surface represented analytically by an Eulerian grid of bric k elements using a Mohr-Coulomb material model. The objective of this paper is to summarize the test and analysis results for the three full-scale crash tests. Simulation models of the airframe which correlate well with the tests are needed for future studies of alternate ELT mounting configurations.

Finite Element Analysis↗

NASA NTRS2023

Experimental Tests to Characterize the Behavior and Properties of IM7-8552 Composite

This document summarizes the test procedures for characterizing the quasi-static (QS), room temperature (RT) behavior of IM7/8552 unidirectional composite material. All testing reported in this document follow applicable ASTM1 test standards as closely as possible, with any deviations reported. The overall objective is to develop a framework for the creation of MAT213 material input for use in the LS-DYNA program (LSTC, 2016). Details of the MAT213 material model and its implementation are available publicly (Goldberg et al., 2015; Harrington et al., 2016; Hoffarth et al., 2016). However, the measured properties can be utilized by most composite impact models.

Mechanical Properties↗

NASA NTRS2023

Finite Element Simulation of Three Full-Scale Crash Tests for Cessna 172 Aircraft

The NASA Emergency Locator Transmitter Survivability and Reliability project was initiated in 2013 to assess the crash performance standards for the next generation of emergency locator transmitter (ELT) systems. Three Cessna 172 aircraft were acquired to perform crash testing at the NASA Langley Research Center Landing and Impact Research Facility. Full-scale crash tests were conducted in the summer of 2015, and each test article was subjected to severe, but survivable, impact conditions including a flare-to-stall during emergency landing and two controlled-flight-into-terrain scenarios. Finite element analyses were performed to numerically simulate the aircraft response to the crash tests. The first test simulated impacting a concrete surface represented analytically by a rigid plane. Tests 2 and 3 simulated impacting a dirt surface represented analytically by an Eulerian grid of brick elements using a Mohr–Coulomb material model. The objective of this paper is to summarize the test and analysis results for the three full-scale crash tests. Simulation models of the airframe that correlate well with the tests are needed for future studies of alternate ELT mounting configurations.

Finite Element Analysis↗

NASA NTRSDate not supplied

Computational investigation on the combined effect of pore attributes on strain concentrators in metal additively manufactured materials

Metal additive manufacturing provides a pathway for creating highly optimized components. However, porosity continues to be a prevalent issue for fatigue performance despite best efforts in optimizing process parameters and postprocessing techniques. This work uses finite element analysis to conduct a parametric study to link various pore attributes (i.e., aspect ratio, orientation, and location) to strain concentration factors (SCF) under elastic/plastic deformation during uniaxial loading. Keyhole and lack-of-fusion pores are idealized by prolate and oblate ellipsoids, respectively. Each simulation of the parametric study assumes a single isolated pore in a Ti-6Al-4V material, modeled with J2-plasticity. A reduced-order model is developed to relate pore attributes to SCF, and then used to quantify the variability in SCF for a given experimentally characterized probability distribution of pore attributes. This reduced-order model can be used in a production environment to provide a first-order evaluation to rapidly screen sub-optimally performing components.

Additive Manufacturing↗

NASA NTRS2025

Direct Impact Split-Hopkinson Bar Experiment for Compression Testing at Strain Rate of 50,000 S-1

A direct impact Hopkinson compression bar experiment is used for compression testing at strain rates in the order of 50,000 s-1. A short specimen mounted on the cross-section surface of a transmitter bar is impacted directly by a projectile (the incident bar in the classical split Hopkinson bar is eliminated).The quantities measured in the test are the projectile impact velocity, the force in the transmitter bar and the strain on the surface of the specimen, which is measured using the digital image correlation method with high-speed cameras. The deformation measurements show a nonuniform deformation in the specimen. To study the strain rate sensitivity properties of the specimen’s material, the experiment is simulated using an assumed material model properties which is validated by comparing the calculated and measured quantities. For aluminum 2024-T351 the results show a small strain rate sensitivity (increase of stress with strain rate) at strain rates above 10,000 s-1.

Nathan Spulak↗

NASA NTRSDate not supplied

Natural Fiber Simulations and Analysis for Composites

As the U.S. government and the aviation industry strive to achieve net-zero carbon emissions by 2050, the Sustainable Manufacturing of Aircraft (SUMAC) project, supported by the Convergent Aeronautics Solutions (CAS) program of the National Aeronautics and Space Administration (NASA), aims to develop sustainably derived thermoplastic composites and manufacturing technologies for future aviation. A multidisciplinary team of experts drives this initiative through a collective effort. The team’s key focus areas are sustainably derived thermoplastic resins, natural fiber reinforcement, composite manufacturing, structural health monitoring, computational materials modeling, and systems analysis. This presentation will give an overview of the SUMAC project. Fiber-scale microscopy analysis characterized fiber cross sections finding that hemp and flax fibers are very deformable and non-circular (circularities of 0.2 were observed), and diameters range from submicron to 20 μm. Fiber shapes range from flattened, with aspect ratios Rlong/Rshort up to 5, to round, Rlong/Rshort =1. And Fiber core perimeters, which likely drives deformability, were calculated Pcore=7 μm. Explicit-fiber yarn simulations, parameterized from single-fiber measurements, resolved and identified slack as a cause for yarn strain-hardening tensile behavior. The bonded network model of PLA, PHA and PA11 resins captures tensile behavior, and can model an infused weave. Computational models of the weave unit cells matched the pattern (including plain, twill and triaxial braid), yarn ply (1to 2), and yarn twist from optical microscopy.

thermoplastic↗

NASA NTRS2026

A Summary of Test and Analysis Results from a Second Lift+Cruise Full-Scale Drop Test

The realization of advanced air mobility markets is enabling new forms of transportation to take shape in the United States and around the world. Though currently in development, as these markets mature, new types of vertical take-off and landing (VTOL) vehicles have been undergoing development for use. There are many factors which must be addressed prior to these types of vehicles becoming viable alternative forms of transportation in these markets. These factors include incorporation into the existing airspaces, the logistics of operating in urban environments, along with numerous factors associated with safety and reliability. To address some of the safety aspects associated with the development of these new types of vehicles, NASA has been conducting research into the performance of an example electric VTOL (eVTOL) aircraft as a part of the Revolutionary Vertical Lift Technology (RVLT) project. Over the course of this research, many aspects including the development of energy absorbing components, the evaluation of seating systems, the development of advanced finite element material model systems and the acquisition of full-scale vehicle impact data were investigated. The report will discuss aspects related to the acquisition of full-scale vehicle data which occurred in the form of a full-scale impact test conducted in the Summer of 2025. This test was on a NASA designed Lift+Cruise composite cabin test article and represented a partial capstone in the entirety of previous eVTOL research conducted for the project. In this test, a variety of experiments were included in order to investigate the effect of a full-scale environment on the experiment results. In parallel, the development of a computational impact model to simulate the full-scale test will be discussed in this report. A model of the Lift+Cruise test article was developed utilizing data collected from previous sub- and full-scale test data and then simulated in the current test environment. The model development, its use in pre-test predictions, and its use in post-test correlation will all be presented. This report will present the test data acquired from the Lift+Cruise test and document several of the results obtained. One intended result is to determine the effect of a complex full-scale crash impact on the identification of occupant injury risk within seat and vehicle designs. A second intended result is to determine whether high-fidelity models can be used with some confidence in the prediction of test events and can allow for additional test cases to be simulated without the need of having to conduct additional tests. The overall goal of the test is to provide the community with data that can be used for design, development or certification efforts, along with providing data on what an example eVTOL crash incident could entail.

energy storage systems↗

NASA NTRSDate not supplied

Natural Fiber Simulations and Analysis for Composites

As the U.S. government and the aviation industry strive to achieve net-zero carbon emissions by 2050, the Sustainable Manufacturing of Aircraft (SUMAC) project, supported by the Convergent Aeronautics Solutions (CAS) program of the National Aeronautics and Space Administration (NASA), aims to develop sustainably derived thermoplastic composites and manufacturing technologies for future aviation. A multidisciplinary team of experts drives this initiative through a collective effort. The team’s key focus areas are sustainably derived thermoplastic resins, natural fiber reinforcement, composite manufacturing, structural health monitoring, computational materials modeling, and systems analysis. This presentation will give an overview of the SUMAC project. Fiber-scale microscopy analysis characterized fiber cross sections finding that hemp and flax fibers are very deformable and non-circular (circularities of 0.2 were observed), and diameters range from submicron to 20 μm. Fiber shapes range from flattened, with aspect ratios Rlong/Rshort up to 5, to round, Rlong/Rshort =1. And Fiber core perimeters, which likely drives deformability, were calculated Pcore=7 μm. Explicit-fiber yarn simulations, parameterized from single-fiber measurements, resolved and identified slack as a cause for yarn strain-hardening tensile behavior. The bonded network model of PLA, PHA and PA11 resins captures tensile behavior, and can model an infused weave. Computational models of the weave unit cells matched the pattern (including plain, twill and triaxial braid), yarn ply (1to 2), and yarn twist from optical microscopy.

thermoplastic↗

NASA NTRSDate not supplied

Practical Tips for Setting Up an LS-DYNA MAT_213 Analysis

Since 2012, NASA has actively contributed to the development and application of the LS-DYNA MAT_213 material model to predict responses under dynamic loading events. This presentation provides a high-level overview of MAT_213 and captures practical tips and suggestions for using it.

MAT_213↗