Modeling the Uptake of Hydrogen Chloride onto Interior Spacecraft Materials
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Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils
Mild steel (AISI 1018) was selected as model cold rolling material and Ti-6A1-4V and Inconel 718 were selected as typical hot rolling and cold rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape rolling process were developed. These models utilized the upper bound and the slab methods of analysis, and were capable of predicting the lateral spread, roll separating force, roll torque, and local stresses, strains and strain rates. This computer-aided design system was also capable of simulating the actual rolling process, and thereby designing the roll pass schedule in rolling of an airfoil or a similar shape.
Lahoti, G. D.↗
Theory, Modeling, Software and Hardware Development for Analytical and Computational Materials Science
The focus of this Cooperative Agreement between the Computational Materials Laboratory (CML) of the Processing Science and Technology Branch of the NASA Glenn Research Center (GRC) and the Department of Theoretical and Applied Mathematics at The University of Akron was in the areas of system development of the CML workstation environment, modeling of microgravity and earth-based material processing systems, and joint activities in laboratory projects. These efforts complement each other as the majority of the modeling work involves numerical computations to support laboratory investigations. Coordination and interaction between the modelers, system analysts, and laboratory personnel are essential toward providing the most effective simulations and communication of the simulation results. Toward these means, The University of Akron personnel involved in the agreement worked at the Applied Mathematics Research Laboratory (AMRL) in the Department of Theoretical and Applied Mathematics while maintaining a close relationship with the personnel of the Computational Materials Laboratory at GRC. Network communication between both sites has been established. A summary of the projects we undertook during the time period 9/1/03 - 6/30/04 is included.
Young, Gerald W.↗
Iapetus and Phoebe as Measured by the Cassini UVIS
The bizarre appearance of Iapetus has long intrigued researchers of this Saturnian moon. The leading hemisphere is very dark and reddish in color at visible-near-IR wavelengths. In contrast, the trailing hemisphere is relatively bright and its near-IR spectrum is dominated by water ice. The severe hemispherical brightness dichotomy has been explained by both endogenic and exogenic models. The primary endogenic model involves eruption of dark material onto the leading hemisphere from the interior of Iapetus. Exogenic models include exposure of dark underlying material by micrometeorite bombardment, contamination of Iapetus leading hemisphere by Titan tholin material, and the coating of the leading hemisphere by Phoebe dust. It has been shown that the dark material on Iapetus leading hemisphere is redder in color at visible wavelengths than Phoebe, which is spectrally gray at visible wavelengths. An additional exogenic model involves the coating of both Iapetus leading hemisphere and Hyperion with material from small retrograde satellites, which are reddish in color at visible wavelengths. We present the first FUV spectra of Iapetus and Phoebe to investigate whether the UV wavelength range can contribute to solving the puzzle of Iapetus.
Hendrix, A. R.↗
Micro-Mechanical Modeling of Ductile Fracture in Welded Aluminum-Lithium Alloys
This study describes a 3-D computational framework to model stable extension of a macroscopic crack under mode I conditions in ductile metals. Material separation occurs through a local fracture mechanism based on the growth and coalescence of micro voids dispersed in the material. The Gurson-Tvergaard plasticity model for void materials describes the eventual loss of material stress capacity under sustained loading. Fixed-sized computational cell elements defined on a thin layer adjacent to the crack plane provide an implicit length scale for continuum damage model. Outside this layer, the material remains undamaged by void growth, consistent with metallurgical observations. The key micro-mechanics parameters are D, the thickness of cell layer, and f 0 , the initial cell porosity.
Ahmed Ibrahim↗
Towards Quantifying and Correlating RTV Intumescence to Entry-Relevant Conditions
Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also adopted to bond instrumentation plugs of temperature and pressure sensors into heatshield’s tiles. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Experimental data has also shown heating rate-dependent swelling (or intumescence) and shrinking of RTV, these volume changes may cause roughness-induced boundary layer transition. Outgassing and surface oxide formation of RTV upon decomposition also occur, which can be sources of contamination of heat shield sensors. This combination of detrimental effects motivates a critical need to develop a high-fidelity model for RTV ablation. As a first critical step in RTV modeling, a comprehensive material properties database for RTV was collected that account for the lack of data in properties such as pyrolysis char yield, shape change, virgin and char porosity. The next step is to quantify the volume change of RTV as a function of temperature. While this was done in previous campaigns, limited data was collected which showed a possible heating rate dependent intumescent behavior. To further understand the intumescence phenomenon of RTV, numerous dedicated experiments were performed at Beamline 8.3.2 of the Advanced Light Source, where RTV samples were heated while X-ray scans were taken in situ. Micro-Computed Tomography scans were taken in situ for low heating rates (≤ 60 °C/min), whereas continuous radiography scans were taken for higher heating rates (≤ 1500 ºC/min). Unconstrained samples and samples constrained in different holders (quartz, graphite, FiberForm and PICA) were tested to determine the change in intumescence due to confinement. Using deep learning techniques, the tomographies and radiographies are segmented to obtain volume change, porosity, pore size distributions and connectivity. From the results obtained, modifications to the previous RTV intumescence model are proposed, along with preliminary comparisons to testing RTV at high-enthalpy facilities.
RTV↗
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.↗
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.↗
One-Dimensional Ablation with Pyrolysis Gas Flow Using a Full Newton's Method and Finite Control Volume Procedure
The development and verification of a one-dimensional material thermal response code with ablation is presented. The implicit time integrator, control volume finite element spatial discretization, and Newton's method for nonlinear iteration on the entire system of residual equations have been implemented and verified for the thermochemical ablation of internally decomposing materials. This study is a continuation of the work presented in "One-Dimensional Ablation with Pyrolysis Gas Flow Using a Full Newton's Method and Finite Control Volume Procedure" (AIAA-2006-2910), which described the derivation, implementation, and verification of the constant density solid energy equation terms and boundary conditions. The present study extends the model to decomposing materials including decomposition kinetics, pyrolysis gas flow through the porous char layer, and a mixture (solid and gas) energy equation. Verification results are presented for the thermochemical ablation of a carbon-phenolic ablator which involves the solution of the entire system of governing equations.
Amar, Adam J.↗
Modeling Off-Nominal Behavior in SysML
Specification and development of fault management functionality in systems is performed in an ad hoc way - more of an art than a science. Improvements to system reliability, availability, safety and resilience will be limited without infusion of additional formality into the practice of fault management. Key to the formalization of fault management is a precise representation of off-nominal behavior. Using the upcoming Soil Moisture Active-Passive (SMAP) mission for source material, we have modeled the off-nominal behavior of the SMAP system during its initial spin-up activity, using the System Modeling Language (SysML). In the course of developing these models, we have developed generic patterns for capturing off-nominal behavior in SysML. We show how these patterns provide useful ways of reasoning about the system (e.g., checking for completeness and effectiveness) and allow the automatic generation of typical artifacts (e.g., success trees and FMECAs) used in system analyses.
fault protection↗
Multiscale Thermal Conductivity Modeling of 3D Woven Composite Thermal Protection System Materials
Novel thermal protection systems (TPS) for re-entry and hypersonic vehicles utilize 3D woven composite materials with blended carbon filament tows (yarns) and a phenolic resin matrix. The presence of continuous carbon fibers provides superior stiffness and strength compared to legacy TPS, while the 3D weave pattern provides a great deal of design flexibility for both in-plane and through thickness thermomechanical behavior. However, modeling of 3D woven composites is notoriously complex and numerically intensive. The present investigation utilizes a unique ultra-efficient approach, known as Multiscale Recursive Micromechanics (MsRM), wherein recursive semi-analytical micromechanics methods are employed at various length scales within the composite. The MsRM approach has recently been extended to solve for the effective thermal conductivity as well as the local temperature and thermal flux fields throughout the composite. Presented model results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures, for a novel 3D woven TPS.
Composite↗
Implementation of Improved Transverse Shear Calculations and Higher Order Laminate Theory Into Strain Rate Dependent Analyses of Polymer Matrix Composites
A numerical procedure has been developed to investigate the nonlinear and strain rate dependent deformation response of polymer matrix composite laminated plates under high strain rate impact loadings. A recently developed strength of materials based micromechanics model, incorporating a set of nonlinear, strain rate dependent constitutive equations for the polymer matrix, is extended to account for the transverse shear effects during impact. Four different assumptions of transverse shear deformation are investigated in order to improve the developed strain rate dependent micromechanics model. The validities of these assumptions are investigated using numerical and theoretical approaches. A method to determine through the thickness strain and transverse Poisson's ratio of the composite is developed. The revised micromechanics model is then implemented into a higher order laminated plate theory which is modified to include the effects of inelastic strains. Parametric studies are conducted to investigate the mechanical response of composite plates under high strain rate loadings. Results show the transverse shear stresses cannot be neglected in the impact problem. A significant level of strain rate dependency and material nonlinearity is found in the deformation response of representative composite specimens.
Zhu, Lin-Fa↗
Experimental Evaluation of Equivalent-Fluid Models for Melamine Foam
Melamine foam is a soft porous material commonly used in noise control applications. Many models exist to represent porous materials at various levels of fidelity. This work focuses on rigid frame equivalent fluid models, which represent the foam as a fluid with a complex speed of sound and density. There are several empirical models available to determine these frequency dependent parameters based on an estimate of the material flow resistivity. Alternatively, these properties can be experimentally educed using an impedance tube setup. Since vibroacoustic models are generally sensitive to these properties, this paper assesses the accuracy of several empirical models relative to impedance tube measurements collected with melamine foam samples. Diffuse field sound absorption measurements collected using large test articles in a laboratory are also compared with absorption predictions determined using model-based and measured foam properties. Melamine foam slabs of various thicknesses are considered.
Allen, Albert R.↗
Finite Difference Time Domain Electromagnetic Scattering from Frequency-Dependent Lossy Materials
During this effort the tasks specified in the Statement of Work have been successfully completed. The extension of Finite Difference Time Domain (FDTD) to more complicated materials has been made. A three-dimensional FDTD code capable of modeling interactions with both dispersive dielectric and magnetic materials has been written, validated, and documented. This code is efficient and is capable of modeling interesting targets using a modest computer work station platform. However, in addition to the tasks in the Statement of Work, a significant number of other FDTD extensions and calculations have been made. RCS results for two different plate geometries have been reported. The FDTD method has been extended to computing far zone time domain results in two dimensions. Finally, the capability to model nonlinear materials has been incorporated into FDTD and validated. The FDTD computer codes developed have been supplied, along with documentation, and preprints describing the other FDTD advances have been included with this report as attachments.
Luebbers, Raymond J.↗
Probabilistic analysis for fatigue strength degradation of materials
This report presents the results of the first year of a research program conducted for NASA-LeRC by the University of Texas at San Antonio. The research included development of methodology that provides a probabilistic treatment of lifetime prediction of structural components of aerospace propulsion systems subjected to fatigue. Material strength degradation models, based on primitive variables, include both a fatigue strength reduction model and a fatigue crack growth model. Linear elastic fracture mechanics is utilized in the latter model. Probabilistic analysis is based on simulation, and both maximum entropy and maximum penalized likelihood methods are used for the generation of probability density functions. The resulting constitutive relationships are included in several computer programs, RANDOM2, RANDOM3, and RANDOM4. These programs determine the random lifetime of an engine component, in mechanical load cycles, to reach a critical fatigue strength or crack size. The material considered was a cast nickel base superalloy, one typical of those used in the Space Shuttle Main Engine.
Royce, Lola↗
Mechanical and Structural Behavior of Granular Material Packed Beds for Space Life Support System Applications
Long-term human mission to space, such as living in International Space Station (ISS), Lunar, and Martian bases, and travel to Mars, must m ake use of Advanced Life Support Systems (ALSS) to generate and recycle critical life supporting elements like oxygen and water. Oxygen Gen eration Assembly (OGA) and Water Processor Assembly (WPA), critical c omponents of ALSS, make use of series of granular material packed beds for generation and recycling of oxygen and water. Several granular m aterials can be used for generation, recycling, processing and recovery of oxygen and water. For example, they may include soft bed media, e.g. ion exchange resins for oxygen generation assembly and hard bed media such as, activated alumina, magchem (Magnesium oxide) and activa ted carbon to remove organic species like ethanol, methanol, and urea from wastewater in Water recovery/processing assembly. These beds are generally packed using a plate-spring mechanism to provide sufficien t compaction to the bed media throughout the course of operation. This paper presents results from an experimental study of a full-scale, 3 8.1 cm (15 inches) long and 3.7 cm (1.44 inches) diameter. activated alumina bed enclosed in a cylinder determining its force-displacement behavior, friction mobilizing force, and axial normal stress distribu tion under various axially applied loads and at different levels of packing. It is observed that force-displacement behavior is non-linear for low compaction level and becomes linear with increase in compaction of the bed media. Axial normal stress distribution along the length of the bed media decreased non-linearly with increase in depth from the loading end of the granular media. This paper also presents experimental results on the amount of particulates generated corresponding to various compaction levels. Particulates generated from each of the tests were measured using standard US sieves. It was found that the p articulates and the overall displacement of the bed media increased with decrease in initial compaction of the bed media. This effect could be attributed to the greater tendency for inter-particle sliding/rub bing due to smaller internal friction angles, as seen from the shear tests, at lesser initial compacted levels. Upon unloading, it was obse rved that there was no change in displacement (especially rebounding) in the bed media. This effect could be attributed to the fact that th e porous activated alumina particles fracture/break upon increase in applied load (during loading phase) and occupy void spaces in between the material grains; thereby leading to settling of the media. The lo ad-displacement curve becomes more linear with increase in initial compaction of the bed media. It is concluded that compaction considerabl y affects the load-displacement behavior of the bed media. A series of tests were also conducted on the packed bed media to determine the f orce required to mobilize the friction between the bed media and the housing cylinder. The results from these tests showed the existence of significant friction between the bed media and the encasing stainles s steel cylinder. Further, it was found that friction effects were more pronounced for media with higher initial compaction. Internal frict ion of the granular media was measured using direct shear apparatus. It was observed that the internal friction increased with increase in initial compaction of the bed media. In this study, a computational m odel (CM) is also developed using finite element software ANSYS to verify experimental results obtained for the distribution of the axial n ormal stress and axial displacement along the length of the full-scal e activated alumina bed media. In the computational model, the granular material is considered to have appropriate failure and frictional c ontact exists between the wall and the granular media. It is observed that the model predicts results closely with the experimental method. The compational results show that the axial normal stress distribution along the length of the activated alumina media decreases non-linea rly from the loading end and is negligible beyond a certain depth. Th is can be attributed to the existence of friction between the walls and the media and that the friction takes up most of the applied load.
Malla, Ramesh B.↗
Energy coupling in catastrophic collisions
The prediction of events leading to the catastrophic collisions and disruption of solar system bodies is fraught with the same difficulties as are other theories of impact events; since one simply cannot perform experiments in the regime of interest. In the catastrophic collisions of asteroids that regime involves bodies of a few tons to hundred of kilometers in diameter, and velocities of several kilometers pre second. For hundred kilometer bodies, gravitational stresses dominate material fracture strengths, but those gravitational stresses are essentially absent for laboratory experiments. Only numerical simulations using hydrocodes can in principle analyze the true problems, but they have their own major uncertainties about the correctness of the physical models and properties. The question of the measure of the impactor and its energy coupling is investigated using numerical code calculations. The material model was that of a generic silicate rock, including high pressure melt and vapor phases, and includes material nonlinearity and dissipation via a Mie-Gruniesen model. A series of calculations with various size ratios and impact velocities are reported.
Holsapple, K. A.↗
Dropping stones in magma oceans - Effects of early lunar cratering
A new methodology is used to calculate the accumulation rate of megaregolith materials for two models of early lunar cratering, both with and without episodes of late cataclysmic cratering. Results show that the pulverization of early rock layers was an important process competing with the formation of a coherent rock lithosphere at the surface of the hypothetical lunar magma ocean. If a magma ocean existed, then its initial cooling was marked by a period of pre-lithospheric chaos in which impacts punched through the initially thin rocky skin, mixing rock fragments with splashed magma. Furthermore, the results show that intense brecciation and pulverization of rock materials must have occurred to a depth of at least tens of kilometers in the first few hundred years of lunar history regardless of whether a 'terminal lunar cataclysm' occurred around 4.0 G.y. ago. The predicted pattern of brecciation and the ages of surviving rock fragments is similar to that actually observed among lunar samples. More reliable dating of basin-forming events and models of rock exhumation and survival are needed in order to understand better the relation between the early intense bombardment of the moon and the samples collected on the moon today.
Hartmann, W. K.↗