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At least 955 records · Page 53

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NASA NTRS2017

Environmental Barrier Coating Fracture, Fatigue and High-Heat-Flux Durability Modeling and Stochastic Progressive Damage Simulation

Advanced environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect emerging light-weight SiC/SiC ceramic matrix composite (CMC) engine components, further raising engine operating temperatures and performance. Because the environmental barrier coating systems are critical to the performance, reliability and durability of these hot-section ceramic engine components, a prime-reliant coating system along with established life design methodology are required for the hot-section ceramic component insertion into engine service. In this paper, we have first summarized some observations of high temperature, high-heat-flux environmental degradation and failure mechanisms of environmental barrier coating systems in laboratory simulated engine environment tests. In particular, the coating surface cracking morphologies and associated subsequent delamination mechanisms under the engine level high-heat-flux, combustion steam, and mechanical creep and fatigue loading conditions will be discussed. The EBC compostion and archtechture improvements based on advanced high heat flux environmental testing, and the modeling advances based on the integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program will also be highlighted. The stochastic progressive damage simulation successfully predicts mud flat damage pattern in EBCs on coated 3-D specimens, and a 2-D model of through-the-thickness cross-section. A 2-parameter Weibull distribution was assumed in characterizing the coating layer stochastic strength response and the formation of damage was therefore modeled. The damage initiation and coalescence into progressively smaller mudflat crack cells was demonstrated. A coating life prediction framework may be realized by examining the surface crack initiation and delamination propagation in conjunction with environmental degradation under high-heat-flux and environment load test conditions.

Mechanical creep and fatigue loading condition↗

NASA NTRS1977

Thermal expansion of an epoxy-glass microsphere composite

The thermal expansion of a composite of epoxy (diglycidyl ether of bisphenol A) and solid glass microspheres was investigated. The microspheres had surfaces which were either untreated or treated with a silicone release agent, an epoxy coupling agent, or a general purpose silane coupling agent. Both room temperature (about 300 K) and elevated temperature (about 475 K) cures were used for the epoxy. Two microsphere size ranges were used, about 50 microns, which is applicable in filled moldings, and about 125 microns, which is applicable as bond line spacers. The thermal expansion of the composites was measured from 300 to 350 K or from 300 to 500 K, depending on the epoxy cure temperature. Measurements were made on composites containing up to .6 volume fraction microspheres. Two predictive models, which required only the values of thermal expansion of the polymer and glass and their specific gravities, were tested against the experimental data. A finite element analysis was made of the thermal strain of a composite cell containing a single microsphere surrounded by a finite-thickness interface.

Price, H. L.↗

NASA NTRS1983

Development of a simplified analytical method for representing material cyclic response

Development of a simplified method for estimating structural inelastic stress and strain response to cyclic thermal loading is presented. The method assumes that high temperature structural response is the sum of time independent plastic and time dependent elastic/creep components. The local structural stress and strain response predicted by linear elastic analysis is modified by the simplified method to predict the inelastic response. The results with simulations by a nonlinear finite element analysis and used time independent plasticity and unified time dependent material model are compared.

Moreno, V.↗

NASA NTRS1984

Design, Fabrication and Test of Composite Curved Frames for Helicopter Fuselage Structure

Aspects of curved beam effects and their importance in designing composite frame structures are discussed. The curved beam effect induces radial flange loadings which in turn causes flange curling. This curling increases the axial flange stresses and induces transverse bending. These effects are more important in composite structures due to their general inability to redistribute stresses by general yielding, such as in metal structures. A detailed finite element analysis was conducted and used in the design of composite curved frame specimens. Five specimens were statically tested and compared with predicted and test strains. The curved frame effects must be accurately accounted for to avoid premature fracture; finite element methods can accurately predict most of the stresses and no elastic relief from curved beam effects occurred in the composite frames tested. Finite element studies are presented for comparative curved beam effects on composite and metal frames.

Lowry, D. W.↗

NASA NTRS2017

Insights into the Behavior of Potential Structural Failures Originating from Localized High Stress Regions in Configurations Relevant to Solid Rocket Motor Nozzles

During the structural certification effort for the Space Launch System solid rocket booster nozzle, it was identified that no consistent method for addressing local negative margins of safety in non-metallic materials had been developed. Relevant areas included bond-line terminations and geometric features in the composite nozzle liners. In order to gain understanding, analog test specimens were designed that very closely mimic the conditions in the actual full scale hardware. Different locations in the nozzle were represented by different analog specimen designs. This paper describes those tests and corresponding results. Finite element analysis results for the tests are presented. Strain gage correlation of the analysis to the test results is addressed. Furthermore, finite fracture mechanics (a coupled stress and energy failure criterion) is utilized to predict the observed crack pop-in loads for the different configurations. The finite fracture mechanics predictions are found to be within a 10% error relative to the average measured pop-in load for each of four configurations. Initiation locations, arrest behaviors, and resistances to further post-arrest crack propagation are also discussed.

McCutcheon, David Matthew↗

NASA NTRSDate not supplied

Novel Test and Analysis Methodology for the Assessment of Joint under Re-entry Environment

Spacecraft thermal protection systems require unique approaches for design verification due to the extreme environments seen during space travel and atmospheric re-entry. In this work, unique considerations for design, analysis, and verification of a tiled heatshield design with material nonlinearity, material property temperature-dependency, material property rate-dependency, and geometric stress concentrations are presented. Such designs require a thorough application of the building block approach to derive appropriate material property datasets, and a novel application of analysis models to aid in the structural verification with testing. The custom application of material rate-dependency in finite element analysis software is presented as a means of leveraging the rate-dependent test data for the material property dataset. Because bonded tile heatshields contain so many design considerations and nonlinearities which often preclude the ability to easily achieve the requisite test factors in qualification testing, a novel sub-element test was developed that amplifies the stress singularity beyond flight conditions. The test achieves an over-test over flight stress conditions. The approach for sub-element coupon design can be extended to other bonded joint designs and can be used in aiding a qualification program.

Pavel Babuska↗

DOE OSTI2023

ECAR-7210 Rev 0 Steady-state Thermo-mechanical Analysis of the MARVEL Fuel Bundle

This document reports the steady-state thermal-hydraulic and static mechanical analyses of the MARVEL micro-reactor core. The objective of this work is to investigate whether fuel-to-fuel contact could occur due to the thermal deformation of the fuel cladding during the normal operation and to assess the resulting impact on the peak cladding temperatures (PCT) if contact occurs. The scope of the work consists of three computational tasks. First, a conjugate heat transfer analysis using computational fluid dynamics (CFD) model was performed to evaluate the PCTs during normal operating conditions. Second, a finite element analysis (FEA) using the cladding temperature field obtained from the CFD analysis was performed to evaluate the thermal deformation of cladding and determine the occurrence of fuel-to-fuel contact. Finally, a CFD analysis of FEA-informed fuel-to-fuel gap (represented by a conservative 0.05 mm uniform gap) was performed to evaluate whether the PCT exceeds the safety criteria.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

NASA NTRS1986

The 15 meter hoop-column antenna dynamics: Test and analysis

A 15 meter model of the hoop-column antenna concept has been vibration tested for model characterization and analytical model verification. Linear finite element analysis predicted the global vibration frequencies accurately. Good agreement between analysis and test data was obtained only after the analytical model was refined using static test data. As structures become more flexible, structural properties determined from static data become more accurate and should be used to update analytical models. Global vibration modes are not significantly affected by the surface mesh which permits simplified analytical models to be used for prediction of global behavior. These reduced models are believed sufficient for preliminary design and controls simulations where only global behavior is desired. The mesh modes were highly damped due to the knit mesh used for the reflector surface. These modes were also highly coupled and very difficult to measure in the laboratory. The inability to fully characterize the antenna mesh modes in the laboratory indicates robust methods for active surface vibration suppression will be needed. Fortunately, the surface mesh exhibits high passive damping which should be beneficial to active control systems.

Belvin, W. Keith↗

NASA NTRS1991

Analysis of delamination onset and growth in curved laminates

Delamination onset and growth from a matrix crack in a curved composite laminate are studied. Finite element analysis is used to determine values of G which can be compared to the interlaminar fracture toughness of the composite for delamination predictions. The delamination is assumed to grow from the matrix crack and to remain straight and perpendicular to the edge. G is larger at the free edge than in the center and increases with delamination growth. Thus, once delamination begins from the matrix crack it should continue around the curved section with no increase in applied load. In the local vicinity of the matrix crack the rate of change of G decreases initially and then begins to increase with a point of inflection in between. Measured failure loads and the interlaminar fracture toughness of the composite are used to show that the point of inflection corresponds to the critical value of G.

Martin, Roderick H.↗

NASA NTRS1996

A Thermostructural Analysis of a Diboride Composite Leading Edge

In an effort to support the design of zirconium diboride composite leading edges for hypersonic vehicles, a finite element model (FEM) of a prototype leading edge was created and finite element analysis (FEA) was employed to assess its thermal and structural response to aerothermal boundary conditions. Unidirectional material properties for the structural components of the leading edge, a continuous fiber reinforced diboride composite, were computed with COSTAR. These properties agree well with those experimentally measured. To verify the analytical approach taken with COSMOS/M, an independent FEA of one of the leading edge assembly components was also done with COSTAR. Good agreement was obtained between the two codes. Both showed that a unidirectional lay-up had the best margin of safety for a simple loading case. Both located the maximum stress in the same region and ply. The magnitudes agreed within 4 percent. Trajectory based aerothermal heating was then applied to the leading edge assembly FEM created with COSMOS/M to determine steady state temperature response, displacement, stresses, and contact forces due to thermal expansion and thermal strains. Results show that the leading edge stagnation line temperature reached 4700 F. The maximum computed failure index for the laminated composite components peaks at 4.2, and is located at the bolt flange in layer 2 of the side bracket. The temperature gradient in the tip causes a compressive stress of 279 ksi along its width and substantial tensile stresses within its depth.

Kowalski, Tom↗

NASA NTRS2008

Software Performs Complex Design Analysis

Designers use computational fluid dynamics (CFD) to gain greater understanding of the fluid flow phenomena involved in components being designed. They also use finite element analysis (FEA) as a tool to help gain greater understanding of the structural response of components to loads, stresses and strains, and the prediction of failure modes. Automated CFD and FEA engineering design has centered on shape optimization, which has been hindered by two major problems: 1) inadequate shape parameterization algorithms, and 2) inadequate algorithms for CFD and FEA grid modification. Working with software engineers at Stennis Space Center, a NASA commercial partner, Optimal Solutions Software LLC, was able to utilize its revolutionary, one-of-a-kind arbitrary shape deformation (ASD) capability-a major advancement in solving these two aforementioned problems-to optimize the shapes of complex pipe components that transport highly sensitive fluids. The ASD technology solves the problem of inadequate shape parameterization algorithms by allowing the CFD designers to freely create their own shape parameters, therefore eliminating the restriction of only being able to use the computer-aided design (CAD) parameters. The problem of inadequate algorithms for CFD grid modification is solved by the fact that the new software performs a smooth volumetric deformation. This eliminates the extremely costly process of having to remesh the grid for every shape change desired. The program can perform a design change in a markedly reduced amount of time, a process that would traditionally involve the designer returning to the CAD model to reshape and then remesh the shapes, something that has been known to take hours, days-even weeks or months-depending upon the size of the model.

Source record↗

NASA NTRS2004

Modeling and Evaluation of Canted Coil Springs as High Temperature Seal Preloading Devices

Future reusable launch vehicles will require advanced structural seals. This includes propulsion seals along edges and hinge lines in hypersonic engines, and control surface seals for movable flaps and elevons on proposed reentry vehicles. Seals must remain in sealing engagement with opposing surfaces, for multiple missions, even though the seal gap may be opening and closing due to thermal and structural loads. To meet this requirement either the seals themselves must be resilient or there must be a resilient structural element behind the seals. Case Western Reserve University is working with NASA s Glenn Research Center to develop more resilient high temperature seal components and preloading devices. Results are presented for a finite element analysis of a canted coil spring that is being considered as a high temperature seal preloading device. This type of spring is a leading candidate due to its ability to provide nearly constant force over a large deflection. The finite element analyses were verified by comparing them to experimental results of canted coil springs of three different stiffnesses, measured at Glenn Research Center. Once validated the parameterized model was combined with a scripting algorithm to assess the effects of key spring design variables (wire diameter, coils per inch, cant amplitude, eccentricity, and spring width) on spring stiffness and maximum Von Mises stress to aid in subsequent design.

Oswald, Jay J.↗

NASA NTRS2014

Hybrid-Wing-Body Vehicle Composite Fuselage Analysis and Case Study

Recent progress in the structural analysis of a Hybrid Wing-Body (HWB) fuselage concept is presented with the objective of structural weight reduction under a set of critical design loads. This pressurized efficient HWB fuselage design is presently being investigated by the NASA Environmentally Responsible Aviation (ERA) project in collaboration with the Boeing Company, Huntington Beach. The Pultruded Rod-Stiffened Efficient Unitized Structure (PRSEUS) composite concept, developed at the Boeing Company, is approximately modeled for an analytical study and finite element analysis. Stiffened plate linear theories are employed for a parametric case study. Maximum deflection and stress levels are obtained with appropriate assumptions for a set of feasible stiffened panel configurations. An analytical parametric case study is presented to examine the effects of discrete stiffener spacing and skin thickness on structural weight, deflection and stress. A finite-element model (FEM) of an integrated fuselage section with bulkhead is developed for an independent assessment. Stress analysis and scenario based case studies are conducted for design improvement. The FEM model specific weight of the improved fuselage concept is computed and compared to previous studies, in order to assess the relative weight/strength advantages of this advanced composite airframe technology

Mukhopadhyay, Vivek↗

DOE OSTI2024

Embedded symmetric positive semi-definite machine-learned elements for reduced-order modeling in finite-element simulations with application to threaded fasteners

Here, we present a machine-learning strategy for finite element analysis of solid mechanics wherein we replace complex portions of a computational domain with a data-driven surrogate. In the proposed strategy, we decompose a computational domain into an “outer” coarse-scale domain that we resolve using a finite element method (FEM) and an “inner” fine-scale domain. We then develop a machine-learned (ML) model for the impact of the inner domain on the outer domain. In essence, for solid mechanics, our machine-learned surrogate performs static condensation of the inner domain degrees of freedom. This is achieved by learning the map from displacements on the inner-outer domain interface boundary to forces contributed by the inner domain to the outer domain on the same interface boundary. We consider two such mappings, one that directly maps from displacements to forces without constraints, and one that maps from displacements to forces by virtue of learning a symmetric positive semi-definite (SPSD) stiffness matrix. We demonstrate, in a simplified setting, that learning an SPSD stiffness matrix results in a coarse-scale problem that is well-posed with a unique solution. We present numerical experiments on several exemplars, ranging from finite deformations of a cube to finite deformations with contact of a fastener-bushing geometry. We demonstrate that enforcing an SPSD stiffness matrix drastically improves the robustness and accuracy of FEM–ML coupled simulations, and that the resulting methods can accurately characterize out-of-sample loading configurations with significant speedups over the standard FEM simulations.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

A Comparative Study of Layer Heating and Continuous Heating Methods on Prediction Accuracy of Residual Stresses in Selective Laser Melted Tube Samples

Thermal distortion and residual stresses are two important factors that affect the quality and reliability of steel parts manufactured by laser powder bed fusion (LPBF) processes. A cost-effective model for evaluation of those heat effects is needed to refine the manufacturing process and provides insights into the product design and heat treatment. In this study, the layer heating method and sophisticated track-layer scanning method were applied to simulate the thermo-mechanical response of IN625 tube parts built by LPBF. Based on the similarity of temperature field in each layer deposit, a swept mesh was constructed to perform the thermal analysis for top layer, with the rest of layers referring to the temperature by node number offsetting. A novel explicit finite element analysis code accelerated by graphics processing unit was used for the massive-element numerical analysis. The computational accuracy and efficiency of the layer heating and track-layer scanning methods were compared in detail. It is shown that layer heating method can efficiently capture the pattern of stress distribution with reasonable accuracy in stress magnitude. The grouped track-layer scanning method can predict the residual stress and strain more accurately at a higher cost (5 ~ 10×). The elastic strain distribution was compared with the measurement by X-ray diffraction, confirming the accuracy of residual stress prediction.

36 MATERIALS SCIENCE↗

DOE OSTI2025

The molten salt tritium transport experiment: A pumped fluoride salt loop for hydrogen isotope experimentation

Molten salt reactors (MSRs) and fusion reactors propose to use molten salts as coolants and breeder blanket materials, respectively. Tritium, however, poses safety concerns in both reactor types due to its ability to permeate through reactor materials and potential for environmental release. This manuscript addresses the tritium transport phenomena in molten salts and presents the design and analysis of the Molten Salt Tritium Transport Experiment (MSTTE). MSTTE is a forced-convection fluoride salt loop intended to measure hydrogen isotope permeation through structural materials in a flowing salt system. In the first phase, MSTTE will use FLiNaK salt and deuterium as surrogates for FLiBe and tritium, with future plans to utilize tritium and FLiBe. MSTTE couples a Copenhagen Atomics pumped salt loop with an external test section that introduces hydrogen isotopes into the loop and measures transport phenomena. The Hydrogen Injection System (HIS) controls hydrogen isotope introduction into the molten salt loop. Here, the permeation test section measures the permeation rate through stainless steel tubing in contact with flowing salt. Computational fluid dynamics (CFD) analysis ensures fully developed salt flow in the permeation test section. MSTTE is modeled with MELCOR-TMAP to predict the permeation rate as a function of experimental variables such as source term, salt flow rate, and salt temperature. Results indicate that the source term is the only parameter with a significant effect on the permeation rate. Pressure drop analysis suggests that the loop should operate below 200 LPM to maintain a pressure drop below 200 kPa. Additionally, finite-element analysis assesses thermal stress during loop operation to ensure the experiment's safe design. MSTTE will provide semi-integral data on tritium transport phenomena in molten salts and serve as a testbed for advancing molten salt technology.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1978

Evaluation and expansion of an analytical model for fatigue of notched composite laminates

The analytical and experimental study performed to expand the existing static and fatigue failure analysis is described. The analytical effort extended the analysis to include interlaminar effects, while the experimental effort developed methods to obtain basic experimental data required as input to the analysis. The static failure analysis for notched laminates was modified to include interlaminar effects near the notch. Three dimensional elastic and two dimensional elasticplastic finite element analysis were performed for some notched laminates.

Ramkumar, R. L.↗

NASA NTRS1987

Manual for Program PSTRESS: Peel stress computation

Described is the use of the interactive FORTRAN computer program PSTRESS, which computes a closed form solution for two bonded plates subjected to applied moments, vertical shears, and in-plane forces. The program calculates in-plane stresses in the plates, deflections of the plates, and peel and shear stresses in the adhesive. The document briefly outlines the analytical method used by PSTRESS, describes the input and output of the program, and presents a sample analysis. The results of the latter are shown to be within a few percent of results obtained using a NASTRAN finite element analysis. An appendix containing a listing of PSTRESS is included.

Barkey, Derek A.↗