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At least 109 records · Page 6

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NASA NTRSDate not supplied

Automated Probabilistic Finite Element Model Calibration Tool Based on Uncertainty Quantification and Machine Learning

Qualification and certification of safety critical parts is a hurdle to the adoption of metallic additively manufactured components for aerospace vehicle applications. Challenges include variability in part properties due to inconsistent defect distribution and microstructure. Understanding of the process through finite element modeling (FEM), and process control through in-situ monitoring, may result in significant improvements; however, solutions useful to manufacturers will require large volumes of data and automated data utilization. Toward this end, a generalizable automated FEM calibration paradigm is developed. This paradigm leverages existing and novel tools from machine learning and uncertainty quantification to enable the automatic calibration of FEMs without requiring prior knowledge of the model performance across input parameter space, including meshing and solver settings, which can require time consuming manual model probing or cause noisy and inconsistent predictions. The result is a probabilistic distribution of calibrated and validated FEM input parameters targeting measured data.

Additive manufacturing model calibration finite el↗

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 NTRSDate not supplied

Classical Flutter Analysis of X-57 Aircraft Mod II, III, and IV Configurations

To support airworthiness assessment of the X-57 electric propulsion demonstrator aircraft, the National Aeronautics and Space Administration (NASA) completed classical flutter analysis of the Mod II, Mod III, and Mod IV aircraft configurations. Aeroelastic analysis was primarily performed using the ZAERO analysis code developed by Zona Technology. Supplemental computational fluid dynamics (CFD) flutter analysis for the Mod III and Mod IV configurations was performed using NASA’s FUN3D software to verify the aeroelastic behavior at deployed flaps conditions. The NASTRAN finite element models (FEMs) used for aeroelastic analysis were developed by NASA. The final Mod II FEM utilized shell elements for the wing and fuselage, and beam elements for the tail and wing control surfaces. For Mod III and Mod IV aircraft models, shell element wing FEMs developed throughout the Mod III/IV wing design cycle were utilized. The fuselage and empennage FEM components were shared between the Mod II, III, and IV aircraft models. ZAERO analyses predicted flutter boundaries were >60% beyond the X-57 flight-test envelope never exceed airspeed (V NE ) for all configurations. Aeroelastic Reynolds-averaged Navier–Stokes (RANS) CFD simulations using FUN3D of the Mod III/IV configurations predicted flap mode instability did not occur until at least speeds of 60% higher than the Mod III/IV maximum flap deployment airspeed (V FE ).

Keerti K. Bhamidipati↗

DOE OSTI2024

Efficient sensitivity analysis of the thermal profile in powder bed fusion of metals using hypercomplex automatic differentiation finite element method

Rapid cyclic temperature fluctuation occurring in powder bed fusion of metals using a laser beam (PBF-LB/M) influences the formation of flaws in printed parts. Consequently, there is a pressing need to enhance the quality of printed parts by developing innovative methodologies that can predict thermal histories and help uncover the intricate relationships between process parameters and thermal profiles. Sensitivity Analysis (SA) emerges as an essential tool for this, offering the potential for process optimization and enhanced quality control. Nonetheless, conventional SA methodologies often incur in excessive computational costs and potential numerical approximation errors. Here, to address this technical challenge, we present a novel method for SA that integrates the HYPercomplex-based Automatic Differentiation (HYPAD) technique with transient thermal simulations conducted via the finite element method (FEM). Leveraging this methodology, we efficiently and accurately perform SA for PBF-LB/M processes in a post-processing step. Compared to traditional methods like Finite Differences (FD), HYPAD-FEM required 96 % less computational time for obtaining sensitivities for 22 process parameters, under a comparative study conducted within the context of the 2018–02 AM benchmark of the National Institute of Standards and Technology. In summary, HYPAD-FEM offers superior efficiency and accuracy in SA over conventional methods, delivering the best sensitivity of a model without the need for step-size selection and problem or parameter-based implementations.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Prediction of residual stresses in additively manufactured parts using lumped capacitance and classical lamination theory

Several industries are interested in Laser Powder Bed Fusion (L-PBF) Additively Manufactured (AM) metal parts because their designs can be made arbitrarily complex while retaining bulk-type material properties. However, the residual stresses (RS) and distortions caused by the heat gradients inherent to L-PBF processes are detrimental to the structural integrity of the parts and must be taken into consideration during the part design cycle. Predicting the state of stresses in as-built 3D printed parts is a difficult problem that is typically approached with the use of transient thermomechanical Finite Element Models (FEMs). However, the nonlinearities associated with AM processes are difficult to capture in these FEMs without increasing the computational cost of the simulation, limiting their ability to be incorporated into practical design cycles. This work presents a novel analytical framework that combines lumped capacitance nonlinear heat transfer with time dependent classical lamination theory to efficiently and accurately predict RS in as-built L-PBF parts without the need of FEMs. The simulation was compared to Neutron Diffraction (ND) residual strain measurements taken at Oak Ridge National Laboratories (ORNL) as well as Synchrotron X-ray Diffraction (XRD) strain data published by the National Institute of Standards and Technology (NIST). The simulation predictions and the experimental data showed excellent agreement for the in-plane strain directions, and general agreement for the out of plane strain component, highlighting an area where further development can be implemented.

42 ENGINEERING↗

DOE OSTI2025

A novel peridynamics-based approach to predict pharmaceutical tablet robustness

The pharmaceutical drug product development process can be greatly accelerated through the use of modeling and simulation techniques to predict the manufacturability and performance of a given formulation. The anticipation and possible mitigation of tablet damage due to manufacturing stresses represents a specific area of interest in the pharmaceutical industry for predicting formulation and tableting performance. While the finite element method (FEM) has been extensively used for predicting the mechanical behavior of powder material in the compaction processes, a shortcoming of the approach is the inherent difficulty to predict discontinuities (e.g., damage or cracking) within a tablet as FEM is a continuum-based approach. In this work, we propose a novel method utilizing peridynamics (PD), a numerical method that can capture discontinuities such as tablet fracture, to predict the evolution of damage and breakage in pharmaceutical tablets. The approach links (1) the finite element method – to elucidate the behavior of powders during die compaction – with (2) the peridynamics modeling technique – to model the discontinuous nature of damage and predict tablet breakage during the critical stages of unloading and ejection from the compression die. This short communication presents a proof of concept including a workflow to calibrate the linked FEM-PD simulation models. Further, it demonstrates promising results from a preliminary experimental validation of the approach. Following further development, this approach could be used to guide the optimization of compression processes through targeted changes to formulation material properties, compression process conditions, and/or tooling geometries to deliver improved process efficiency and tablet robustness.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Finite-element-based simulations of electrodes for CO 2 cascade reduction reactions

The multielectron reduction of CO 2 to liquid fuels could be a path to scalable energy storage, but reaching this goal requires major advances in catalysis and systems engineering. Cascade catalysis, which couples sequential reactions without isolating intermediates, has emerged as a promising route to enhance selectivity and efficiency in CO 2 reduction (CO 2 R). In this review, we examine how finite-element-based simulations of continuum model [finite element method (FEM)] approaches are being used to analyze and guide CO 2 R cascade systems. We first outline the fundamentals of cascade catalysis and recent advances in catalytic materials (metallic, molecular, and hybrid architectures). We then focus on FEM developments at the electrode and device scales, emphasizing how these models capture transport phenomena, local microenvironments, and geometry-dependent effects. To clarify design principles, we present case studies of cascade electrodes organized in systems without and with integrated semiconductors. We further emphasize the integration of FEM with multiscale frameworks (density functional theory, molecular dynamics, kinetic Monte Carlo) and its role in bridging atomic-level insights with device-level performance. Finally, we identify current limitations and future prospects, including improved boundary conditions, coupling with operando experiments, and machine learning-accelerated model development. Together, these insights provide design principles for next-generation CO 2 R cascade systems for efficient solar fuel production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Understanding the Interactions of Multiple Pits Under Freely Corroding Conditions

The interactions of two propagating pits on a single cathode surface were evaluated across variations in chloride concentration, water layer (WL), pit sizes, separation distance (x 2 ), and cathode size (L Cath ) under freely corroding conditions using Finite Element Methods (FEM). Calculated FEM current was utilized to predict stability based on the Galvele pit stability product. FEM predictions were utilized to train a neural network machine learning model for rapid stability predictions. Pit one is in the center of a circular cathode while pit two moves radially from the center pit. With two pits, the overall current in each pit is decreased with respect to a single pit, however, the total current is increased. Increasing WL and L Cath generally increased overall current in each pit and increased predicted maximum pit sizes. Increasing x 2 decreased current in pit two due to less cathode being available to support dissolution in proximity to pit two. Increasing chloride concentration from 0.6 to 3 M NaCl increased current, while increasing from 3 to 5.3 M NaCl decreased current. An overall increase in predicted pit size with increase in chloride concentration is predicted. A machine learning model was created to predict current and maximum pit size and captured underlying physics and predicted stability across the multidimensional parameter space.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Uncertainty-Based Design: Finite Element and Explainable Machine Learning Modeling of Carbon–Carbon Composites for Ultra-High Temperature Solar Receivers

Design under uncertainty has significantly grown in research developments during the past decade. Additionally, machine learning (ML) and explainable ML (XML) have offered various opportunities to provide reliable predictable models. The current article investigates the use of finite element modeling (FEM), ML and XML predictions, and uncertain-based design of carbon-carbon (C-C) composites for use in ultra-high temperatures. A C-C composite concentrating solar power (CSP) as a microvascular receiver is considered as a case study. These C-C composites are fiber composites with directly integrated carbonized microchannels to form a lightweight, high-absorptivity material that includes an embedded microvascular network of channels. The topology of these microchannels is engineered to optimize heat transfer to a supercritical carbon dioxide (sCO2) heat transfer fluid. The mechanical characterization of C-C composites is highly challenging. Thus, designing every component made of C-C composites for ultra-high temperature applications needs an uncertainty-based analysis. As a part of a comprehensive project on the development of a novel carbonized microvascular C-C composite, this paper explores C-C composite sensitivity analysis, FEM, ML prediction, and XML analysis. The resulting composite can then be carbonized and coated with an oxidation-resistant coating to form a thermally efficient and mechanically robust C-C composite. An ANSYS 3-D-FE model was used to analyze the CSP’s stress/strain. To consider the variability in the mechanical and thermal properties of C-C composites, various mechanical properties are considered as the ANSYS FEM’s input. A synthetic dataset from 730 ANSYS runs was produced to feed into the ML and XML algorithms for uncertainty analysis and prediction. The ML and XML algorithms could accurately predict the CSP stresses/strains.

Daghigh, Vahid (ORCID:0000000298941620)↗

NASA NTRS1979

Wave propagation in ducts using the finite element method

The paper outlines a comparative study designed to assess and compare the accuracy of the finite element method (FEM) for linear and quadratic elements as applied to problems in duct acoustics. The acoustic disturbances are assumed to be irrotational and isentropic so that the problem can be formulated in terms of the acoustic velocity potential. It is shown that for the case of plane wave propagation in a hard-walled annular cylinder, the accuracy of the FEM solution can be increased at higher frequencies by using quadratic triangular elements instead of linear triangular elements. Evidence is presented to enhance the confidence in applying the developed FEM by comparing results with those obtained by other independently developed numerical approaches such as an integral equation technique and a finite difference method.

Majjigi, R. K.↗

NASA NTRS1986

Comparative efficiency of finite, boundary and hybrid element methods in elastostatics

The comparative computational efficiencies of the finite element (FEM), boundary element (BEM), and hybrid boundary element-finite element (HBFEM) analysis techniques are evaluated for representative bounded domain interior and unbounded domain exterior problems in elastostatics. Computational efficiency is carefully defined in this study as the computer time required to attain a specified level of solution accuracy. The study found the FEM superior to the BEM for the interior problem, while the reverse was true for the exterior problem. The hybrid analysis technique was found to be comparable or superior to both the FEM and BEM for both the interior and exterior problems.

Schwartz, C. W.↗

NASA NTRS1986

Research related to improved computer aided design software package

The comparative computational efficiencies of the finite element (FEM), boundary element (BEM), and hybrid boundary element-finite element (HVFEM) analysis techniques are evaluated for representative bounded domain interior and unbounded domain exterior problems in elastostatics. Computational efficiency is carefully defined in this study as the computer time required to attain a specified level of solution accuracy. The study found the FEM superior to the BEM for the interior problem, while the reverse was true for the exterior problem. The hybrid analysis technique was found to be comparable or superior to both the FEM and BEM for both the interior and exterior problems.

Walston, W. H., Jr.↗

NASA NTRS1986

Summary of AH-1G flight vibration data for validation of coupled rotor-fuselage analyses

Under a NASA research program designated DAMVIBS (Design Analysis Methods for VIBrationS), four U. S. helicopter industry participants (Bell Helicopter, Boeing Vertol, McDonnell Douglas Helicopter, and Sikorsky Aircraft) are to apply existing analytical methods for calculating coupled rotor-fuselage vibrations of the AH-1G helicopter for correlation with flight test data from an AH-1G Operational Load Survey (OLS) test program. Bell Helicopter, as the manufacturer of the AH-1G, was asked to provide pertinent rotor data and to collect the OLS flight vibration data needed to perform the correlations. The analytical representation of the fuselage structure is based on a NASTRAN finite element model (FEM) developed by Bell which has been extensively documented and correlated with ground vibration tests.The AH-1G FEM was provided to each of the participants for use in their coupled rotor-fuselage analyses. This report describes the AH-1G OLS flight test program and provides the flight conditions and measured vibration data to be used by each participant in their correlation effort. In addition, the mechanical, structural, inertial and aerodynamic data for the AH-1G two-bladed teetering main rotor system are presented. Furthermore, modifications to the NASTRAN FEM of the fuselage structure that are necessary to make it compatible with the OLS test article are described. The AH-1G OLS flight test data was found to be well documented and provide a sound basis for evaluating currently existing analysis methods used for calculation of coupled rotor-fuselage vibrations.

Dompka, R. V.↗

NASA NTRS1987

Space station integrated wall design and penetration damage control

The analysis code BUMPER executes a numerical solution to the problem of calculating the probability of no penetration (PNP) of a spacecraft subject to man-made orbital debris or meteoroid impact. The codes were developed on a DEC VAX 11/780 computer that uses the Virtual Memory System (VMS) operating system, which is written in FORTRAN 77 with no VAX extensions. To help illustrate the steps involved, a single sample analysis is performed. The example used is the space station reference configuration. The finite element model (FEM) of this configuration is relatively complex but demonstrates many BUMPER features. The computer tools and guidelines are described for constructing a FEM for the space station under consideration. The methods used to analyze the sensitivity of PNP to variations in design, are described. Ways are suggested for developing contour plots of the sensitivity study data. Additional BUMPER analysis examples are provided, including FEMs, command inputs, and data outputs. The mathematical theory used as the basis for the code is described, and illustrates the data flow within the analysis.

Coronado, A. R.↗

NASA NTRS1987

Sizing and shape design sensitivity analysis using a hybrid finite element code

The practical (software) implementation of the theoretical FEM-based design sensitivity analysis method of Haug et al. (1986) is described and demonstrated. The fundamental principles of the method are reviewed; the problems involved in applying it to the Engineering Analysis Language (EAL) hybrid FEM code (Whetstone, 1983) are discussed; the formulations for beams, plate bending, and built-up structures are given in detail; programming aspects are considered; and numerical results for sample problems are presented in extensive tables. It is shown that the use of a data-base management system with an FEM such as EAL makes it possible to obtain accurate sizing and shape design sensitivity information using only one program with one data base.

Dopker, Bernhard↗

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 NTRS1990

Static aeroelastic analysis of composite wing

A static aeroelastic analysis capability that can predict aerodynamic loads for the deformed shape of the composite wing has been developed. The finite element method (FEM) was used for composite plate structural analysis, and the linear vortex lattice method (VLM) was used for steady aerodynamic analysis. The final deformed shape of the wing due to applied forces is determined by iterative manner using FEM and VLM. FEM and VLM analysis are related by a surface spline interpolation procedure. The wing with Gr/Ep composite material has been investigated to see the wing deformation effect. Aerodynamic load change due to wing flexibility has been investigated. Also, the effect of fiber orientation and sweep angle on the deformation pattern and aerodynamic coefficients are examined. For a certain fiber orientation, the deflection and aerodynamic loading of the composite wing is very much reduced. The swept forward wing has more significant effect of wing flexibility on aerodynamic coefficient than the swept back wing does.

Lee, IN↗

NASA NTRS1993

The NASA/industry Design Analysis Methods for Vibrations (DAMVIBS) program : Bell Helicopter Textron accomplishments

Accurate vibration prediction for helicopter airframes is needed to 'fly from the drawing board' without costly development testing to solve vibration problems. The principal analytical tool for vibration prediction within the U.S. helicopter industry is the NASTRAN finite element analysis. Under the NASA DAMVIBS research program, Bell conducted NASTRAN modeling, ground vibration testing, and correlations of both metallic (AH-1G) and composite (ACAP) airframes. The objectives of the program were to assess NASTRAN airframe vibration correlations, to investigate contributors to poor agreement, and to improve modeling techniques. In the past, there has been low confidence in higher frequency vibration prediction for helicopters that have multibladed rotors (three or more blades) with predominant excitation frequencies typically above 15 Hz. Bell's findings under the DAMVIBS program, discussed in this paper, included the following: (1) accuracy of finite element models (FEM) for composite and metallic airframes generally were found to be comparable; (2) more detail is needed in the FEM to improve higher frequency prediction; (3) secondary structure not normally included in the FEM can provide significant stiffening; (4) damping can significantly affect phase response at higher frequencies; and (5) future work is needed in the areas of determination of rotor-induced vibratory loads and optimization.

Cronkhite, James D.↗