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At least 1,171 records · Page 65

Modeling lattice rotation fields from discrete crystallographic slip bands in superalloys

Here in this work, we investigate the relationship between an intense slip band (ISB) and the zone of large lattice rotations that forms ahead of the tip of the ISB. We develop a crystal plasticity finite element model of a discrete ISB lying within an oligocrystalline assembly and calculate the local crystalline stress and lattice rotation fields generated by the ISB. The calculations demonstrate that, first, a region of severe lattice rotations, commonly referred to as a microvolume, does not form without the ISB, and second, large amounts of accumulated slip in the ISB are required to enlarge the microvolume to sizes and rotation magnitudes observed experimentally. Ahead of the ISB tip, the quintessential plastic zone always forms, but the atypical microvolume forms when non-concentrated and spatially diffuse slip is activated by the ISB-induced stress field. This result suggests that the detrimental ISB/microvolume pair will likely appear in pairs of crystals in which transmission of the slip from the ISB is severely blocked by the grain boundary, a hypothesis that we verify with a few target cases.

36 MATERIALS SCIENCE↗

Aeroelastic Optimization Study Based on the X-56A Model

One way to increase the aircraft fuel efficiency is to reduce structural weight while maintaining adequate structural airworthiness, both statically and aeroelastically. A design process which incorporates the object-oriented multidisciplinary design, analysis, and optimization (MDAO) tool and the aeroelastic effects of high fidelity finite element models to characterize the design space was successfully developed and established. This paper presents two multidisciplinary design optimization studies using an object-oriented MDAO tool developed at NASA Armstrong Flight Research Center. The first study demonstrates the use of aeroelastic tailoring concepts to minimize the structural weight while meeting the design requirements including strength, buckling, and flutter. Such an approach exploits the anisotropic capabilities of the fiber composite materials chosen for this analytical exercise with ply stacking sequence. A hybrid and discretization optimization approach improves accuracy and computational efficiency of a global optimization algorithm. The second study presents a flutter mass balancing optimization study for the fabricated flexible wing of the X-56A model since a desired flutter speed band is required for the active flutter suppression demonstration during flight testing. The results of the second study provide guidance to modify the wing design and move the design flutter speeds back into the flight envelope so that the original objective of X-56A flight test can be accomplished successfully. The second case also demonstrates that the object-oriented MDAO tool can handle multiple analytical configurations in a single optimization run.

flutter constraints↗

Real-Time State Estimation of Structural Modes for an Aeroelastic Wind Tunnel Model

A method is presented for estimating displacements, velocities, and accelerations of structural modes in generalized coordinates from measured sensor data in real time. Specifically, strain data from conventional strain gauges and fiber optic strain sensors (FOSS) were combined with the strain modes (obtained from a finite element model) in a least-squares estimator to produce structural mode displacement estimates and uncertainties. Likewise, accelerometer data were combined with displacement mode shapes in a second least-squares estimator to produce structural mode acceleration estimates. A Kalman filter was then used to refine the displacement estimates and obtain velocity estimates. The method was applied to the half-span wind tunnel test article used in the NASA-Boeing collaboration called the Integrated Adaptive Wing Technology Maturation (IAWTM) project. The technique was found to be useful for real-time control and system identification applications.

Jared A. Grauer↗

Scaling effects in the static large deflection response of graphite-epoxy composite beams

Scaling effects in the large deflection response of graphite-epoxy composite beams was investigated. Eight different scale model beams ranging from 1/6 to full-scale were subjected to an eccentric axial compressive load to promote large bending deformations and failures. Beams having laminate stacking sequences including unidirectional, angle ply, cross ply, and quasi-isotropic were tested to examine a wide variety of composite response and failure modes. The model beams were loaded under scaled test conditions until catastrophic failure. Data acquired included load, end displacement, and strain measurements, and qualitative failure measurements. The experimental data is compared to a large rotation beam analysis and a finite element model analysis. Results from the tests indicate that the beam response becomes nonlinear. Failure modes are consistent between scale models within a laminate family, however, a significant scale effect is observed in strength of the scaled beams.

Jackson, Karen E.↗

Multidisciplinary Approach to Aerospike Nozzle Design

A model of a linear aerospike rocket nozzle that consists of coupled aerodynamic and structural analyses has been developed. A nonlinear computational fluid dynamics code is used to calculate the aerodynamic thrust, and a three-dimensional finite-element model is used to determine the structural response and weight. The model will be used to demonstrate multidisciplinary design optimization (MDO) capabilities for relevant engine concepts, assess performance of various MDO approaches, and provide a guide for future application development. In this study, the MDO problem is formulated using the multidisciplinary feasible (MDF) strategy. The results for the MDF formulation are presented with comparisons against separate aerodynamic and structural optimized designs. Significant improvements are demonstrated by using a multidisciplinary approach in comparison with the single-discipline design strategy.

Korte, J. J.↗

Status of the KTH-NASA Wind-Tunnel Test for Acquisition of Transonic Nonlinear Aeroelastic Data

This paper presents a status report on the collaboration between the Royal Institute of Technology (KTH) in Sweden and the NASA Langley Research Center regarding the design, fabrication, modeling, and testing of a full-span lighter configuration in the Transonic Dynamics Tunnel (TDT). The goal of the test is to acquire transonic limit-cycle- oscillation (LCO) data, including accelerations, strains, and unsteady pressures. Finite element models (FEMs) and aerodynamic models are presented and discussed along with results obtained to date.

Silva, Walter A.↗

Chromium Poisoning ERMINE Model Data

This is the data from the paper "Systematic and Predictive Trends to Chromium Poisoning in Solid Oxide Fuel Cell Cathodes" by Hokon Kim et al., appearing in the Journal of Power Sources. The files here are the microstructures, mesh files, and outputs from the ERMINE finite element model of chromium poisoning in SOFC cathodes. Further description can be found in Readme.rtf and in the paper..

Chromium,SOFC↗

Precise Determination of the Zero-Gravity Surface Figure of a Mirror without Gravity-Sag Modeling

The zero-gravity surface figure of optics used in spaceborne astronomical instruments must be known to high accuracy, but earthbound metrology is typically corrupted by gravity sag. Generally, inference of the zero-gravity surface figure from a measurement made under normal gravity requires finite-element analysis (FEA), and for accurate results the mount forces must be well characterized. We describe how to infer the zero-gravity surface figure very precisely using the alternative classical technique of averaging pairs of measurements made with the direction of gravity reversed. We show that mount forces as well as gravity must be reversed between the two measurements and discuss how the St. Venant principle determines when a reversed mount force may be considered to be applied at the same place in the two orientations. Our approach requires no finite-element modeling and no detailed knowledge of mount forces other than the fact that they reverse and are applied at the same point in each orientation. If mount schemes are suitably chosen, zero-gravity optical surfaces may be inferred much more simply and more accurately than with FEA.

measurements↗

Finite element meshing of ANSYS (trademark) solid models

A large scale, general purpose finite element computer program, ANSYS, developed and marketed by Swanson Analysis Systems, Inc. is discussed. ANSYS was perhaps the first commercially available program to offer truly interactive finite element model generation. ANSYS's purpose is for solid modeling. This application is briefly discussed and illustrated.

Kelley, F. S.↗

MODELING A SPENT NUCLEAR FUEL CASK SEISMIC TEST

The US Department of Energy Spent Fuel and Waste Science and Technology (SFWST) program is planning to conduct a series of full-scale shake table tests to simulate hypothetical earthquake conditions and record the response of surrogate spent nuclear fuel (SNF) assemblies in a canister dry storage system mockup. The shake table motions will represent a range of hypothetical earthquake conditions at hypothetical locations in the continental US to generally define the range of mechanical loads that SNF can be expected to experience during extended dry storage periods. The earthquake conditions will represent seismic hazards in the 2,000-to-20,000-year return period range. The test will use instrumented pressurized water reactor fuel assemblies with surrogate mass inside the fuel rods instead of radioactive fuel pellets. Dummy assemblies with similar mass and dimensions to actual fuel assemblies will occupy the rest of the fuel assembly locations in a SNF canister that holds 32 fuel assemblies. The canister will be located inside a mockup vertical concrete cask. Instrumentation will record the motion of the major components of the complex dynamic system, and strain gauges will be used to record the cladding strain at select locations. Preparations for the test require modeling predictions to identify the range of response of the system and to help select specific earthquake cases to be simulated on the shake table from a large set of potential cases. This paper describes the pretest nonlinear finite element modeling efforts that have been completed to date, including cask system level modeling and fuel assembly modeling in LS-DYNA. The cask system level models are critical for anticipating sliding or tipping of an unanchored cask during the test. The fuel assembly model is needed to estimate the range of cladding strain response and fuel assembly structural response to be expected during the test and cladding strain measurements will be key metrics for model validation and the development of modeling best practices after the test is concluded.

Klymyshyn, Nicholas A.↗

A mechanistic model for creep and thermal aging in Alloy 709

This report describes a physics-based model for creep and thermal aging in Alloy 709. Alloy 709 is an advanced austenitic alloy, targeted for use in future Sodium Fast Reactors (SFRs) and other advanced reactors. The material has superior high temperature properties compared to currently qualified 316 and 304 stainless steels. However, the available creep and thermal aging test database for Alloy 709 is significantly more limited compared to the historical materials. The physics-based model developed here is one way to accelerate the qualification of the material by providing more accurate long-term predictions for creep properties and thermal aging, compared to current empirical time-extrapolate techniques. The crystal plasticity finite element model is used to predict the deformation and failure of alloy 709. The same setup for the CPFE model is used in both the baseline model calibration process and the simulation campaigns for parameter inference. Specific constitutive choices are made for Alloy 709 to capture the primary deformation mechanisms. The dislocation creep formulation developed by Hu and Cocks is extended to account for coupled precipitation formation and the grain boundary cavitation model developed by Sham, Needleman, et al. is used to model grain boundary cavitation-induced failure. A novel update algorithm is proposed to render the semi-discrete constitutive update for the Sham-Needleman model unconditionally stable. A progressive calibration approach is adopted based on the observations that several types of material responses can be effectively decoupled. A surrogate model is trained based on full-fledged CPFE simulations to accelerate the forward model evaluations, and stochastic variational inference (SVI) is used to calibrate the unknown microstructural model parameters. The calibrated mechanistic model is used to predict the long-term creep life of Alloy 709, and the predictions are compared against classical empirical approaches.

36 MATERIALS SCIENCE↗

Thermal-vacuum testing and in-situ optical alignment measurements of the HALOE telescope/sun sensor assembly

Design features, test data and projected performance levels of the telescope/sun sensor assembly for the Halogen Occultation Experiment (HALOE) on board the Upper Atmosphere Research Satellite are described. HALOE will gather data on stratospheric chemical species with an IR telescope pointed through the atmosphere at the sun during occultation periods. The pointing accuracy will need to be 1 arcmin elevation and 1.6 arcmin azimuthal. Adjustments of the gimbaled instrument are guided by a sun sensor and its associated electronics. The components were subjected to thermal-vacuum, optical boresight stability tests and the data generated were compared with a finite element model of the telescope and sun sensor. The tests consisted of exposure to various thermal gradients while the telescope and sun sensor alignments were tracked by optical deflectometry. The thermal behavior was compared with predictions made with a finite difference model. Alignments were within tolerable ranges and the thermal behavior model was concluded valid for predicting the thermal behavior of orbiting instruments.

Foss, R. A.↗

Modeling the Effect of Damage on the Electrical Resistivity of Melt-Infiltrated SiC/SiC Composites

Electrical resistivity (ER) measurements are a possible health monitoring technique for CMC components in future aerospace applications. In order to use ER measurements to detect and identify damage, it is necessary to understand how each specific damage state will affect the ER response. In this paper, finite element models are developed and applied to quantify the effect of specific damage states on the electrical resistivity response in a melt-infiltrated silicon carbide (SiC) fiber-reinforced silicon carbide composite. The electrical resistivity of several damage states are calculated by simulating the electric current flow through the damaged micro-structure. This is achieved by performing the numerical solution of the steady-state conservation of charge density equation. Numerical results reveal that cracking of the inter-tow matrix has the most profound effect on the composite electrical resistivity. Also, fiber/matrix debonding at matrix cracks in the 0° tows (tows aligned with the loading direction) may cause a significant increase in the electrical resistivity, but only if the fiber coating resistivity is 1000 Ω-cm or less. Cracks in the 90° tows and the crack opening displacement have very little effect on the composite electrical resistivity.

finite element analysis↗

Evaluation of Transverse Thermal Stresses in Composite Plates Based on First-Order Shear Deformation Theory

A postprocessing procedure is presented for the evaluation of the transverse thermal stresses in laminated plates. The analytical formulation is based on the first-order shear deformation theory and the plate is discretized by using a single-field displacement finite element model. The procedure is based on neglecting the derivatives of the in-plane forces and the twisting moments, as well as the mixed derivatives of the bending moments, with respect to the in-plane coordinates. The calculated transverse shear stiffnesses reflect the actual stacking sequence of the composite plate. The distributions of the transverse stresses through-the-thickness are evaluated by using only the transverse shear forces and the thermal effects resulting from the finite element analysis. The procedure is implemented into a postprocessing routine which can be easily incorporated into existing commercial finite element codes. Numerical results are presented for four- and ten-layer cross-ply laminates subjected to mechanical and thermal loads.

Rolfes, R.↗

Nondestructively Visualizing and Understanding the Mechano-Electro-chemical Origins of “Soft Short” and “Creeping” in All-Solid-State Batteries

All-solid-state Li-metal batteries (ASLMBs) represent a significant breakthrough in the quest to overcome limitations associated with traditional Li-ion batteries, particularly in energy density and safety aspects. However, widespread implementation is stymied due to a lack of profound understanding of the complex mechano-electro-chemical behavior of Li metal in the ASLMBs. Herein, operando neutron imaging and X-ray computed tomography (XCT) are leveraged to nondestructively visualize Li behaviors within ASLMBs. This approach offers real-time observations of Li evolutions, both pre- and post- occurrence of a “soft short”. The coordination of 2D neutron radiography and 3D neutron tomography enables charting of the terrain of Li metal deformation operando. Concurrently, XCT offers a 3D insight into the internal structure of the battery following a “soft short”. Despite the manifestation of a “soft short”, the persistence of Faradaic processes is observed. To study the elusive “soft short”, phase field modeling is coupled with electrochemistry and solid mechanics theory. The research unravels how external pressure curbs dendrite growth, potentially leading to dendrite fractures and thus uncovering the origins of both “soft” and “hard” shorts in ASLMBs. Furthermore, by harnessing finite element modeling, it dive deeper into the mechanical deformation and the fluidity of Li metal.

25 ENERGY STORAGE↗

Sensor Development for Liquid Water Detection in Dry Storage Casks: FY 2023 Status

Modeling efforts were undertaken in fiscal year (FY) 2023 to evaluate the feasibility and capability for sensing of liquid water inside canister-based dry cask storage systems (DCSSs). The focus was on the development of full-scale finite element models (FEMs) of ultrasound propagation through DCSS canister components. For these initial investigations, simulation of the baseplate component was targeted, envisioning water collection at the bottom of a vertically oriented canister. The effects of internal canister components (i.e., fuel basket, fuel assemblies) on ultrasound propagation in the baseplate component were evaluated in these efforts. The environment inside a DCSS confinement is intended to be inert and free of water to prevent potential corrosion of used fuel cladding or other internal hardware. Spent fuel assemblies are dried, after storage in water pools, to make sure water has been removed from assembly cavities. However, there is some uncertainty about the amount of residual water potentially left behind in a DCSS after drying processes, because water can become trapped in cavities or other small crevices in the surfaces formed by the fuel cladding, fuel assemblies, and other internal hardware components. Considering the complex space- and time-dependent temperature profiles in DCSSs, water may be in a liquid or gas phase depending on its location in the cask and how long the cask has been in storage. Evacuating most water and oxidizing agents contained within a canister is recommended by NUREG-1536 (NRC 2010), which covers DCSSs. As summarized by Salazar et al. (2020), existing guidance typically relies on achievable vacuum pumping pressures sustained over a hold period as a signal of dryness and water removal. However, time series data about water removal from full-scale commercial drying procedures are lacking (Hanson and Alsaed 2019). A review of drying specifications from several vendors led to the conclusion that if the specifications are followed correctly, the residual moisture in DCSSs should present an insignificant risk of cladding degradation (Knoll and Gilbert 1987). A more recent analysis concluded that much larger quantities of residual water could remain in DCSSs, but the amount would still not be expected to lead to significant corrosion of fuel cladding or other internal components (Jung et al. 2013). Industry drying procedures are mostly prescriptive in nature, and operational issues arising during the process could result in incomplete drying. A summary of operational issues and potential negative effects of residual water is provided by Salazar et al. (2019). Experimental efforts are ongoing to validate the extent of water removal in a DCSS based on drying procedures used at nuclear power plants through well-designed investigations of drying process efficacy and water retention (Durbin et al. 2021; Pulido et al. 2022a, Pulido et al. 2022b). This has been approached by simulating limited portions of a DCSS internal volume and fuel assemblies. So far, these efforts have focused on the effects of potential water trapping in the dashpot region of control rod guide tubes but are expected to be expanded to include the effects of other internal hardware features and failed fuel rod cladding. A method for detection and measurement of liquid water (Meyer et al. 2022; Meyer et al. 2021), in tandem with the drying information gained through experimental investigations, provides comprehensive bases for understanding the internal conditions of DCSSs and provides technical information to support licensing decisions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

High Fidelity Modeling of Evolutionary Structures in IMOS

A methodology is proposed for testing, modal identification, and model correlation of structures which are assembled in an evolutionary manner. The methodology prescribes initial testing of a base structure without any attached components. The experimental modal properties are used to update the physical properties of the base structure finite element model using a Bayesian Estimation Technique (BET). The BET is implemented in METLAB using IMOS functions. As components are added to the base structure, additional tests are performed. Three testing options are proposed, all of which enable estimation of the physical parameters of the components alone. Furthermore, improvements to the original BET implementation have been made, which contribute to higher fidelity models and more efficient computational times.

structures testing assembling modeling BET Bayesia↗

Mixed Models and Reduction Techniques for Large-Rotation, Nonlinear Analysis of Shells of Revolution with Application to Tires

An effective computational strategy is presented for the large-rotation, nonlinear axisymmetric analysis of shells of revolution. The three key elements of the computational strategy are: (1) use of mixed finite-element models with discontinuous stress resultants at the element interfaces; (2) substantial reduction in the total number of degrees of freedom through the use of a multiple-parameter reduction technique; and (3) reduction in the size of the analysis model through the decomposition of asymmetric loads into symmetric and antisymmetric components coupled with the use of the multiple-parameter reduction technique. The potential of the proposed computational strategy is discussed. Numerical results are presented to demonstrate the high accuracy of the mixed models developed and to show the potential of using the proposed computational strategy for the analysis of tires.

Noor, A. K.↗