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DOE OSTI2019

Combined crystal plasticity and grain boundary modeling of creep in ferritic-martensitic steels: I. Theory and implementation

This paper presents a physically-based microstructural model for creep rupture at 600 degrees °C for Grade 91 steel. The model includes constitutive equations that reflect various observed phenomena in Grade 91, and it is incorporated into a mesoscale finite element model with explicit geometry for the prior austenite grains and grain boundaries. Creep within the grains is represented using crystal plasticity for dislocation motion and recovery along with linear viscous diffusional creep for point defect diffusion. The grain boundary models include physics-based models for cavity growth and nucleation that accurately capture tertiary creep and creep rupture. Simulations of creep at 100 MPa are performed, and the contribution of each mechanism is analyzed. The overarching goal is to gain a mechanistic understanding of the material to improve the prediction of creep rupture for long service lives in elevated temperature operating conditions. The creep response of the material at different stress levels, stress states, and temperatures is studied in Part 2 of this paper in order to determine the implications of the simulations on high temperature design practice. Furthermore, the second part explores the effect of triaxial stress states on the creep response and finds a transition from notch-strengthening behavior at high stress to notch-weakening behavior at lower stresses.

36 MATERIALS SCIENCE↗

DOE OSTI2024

STRUCTURAL MODELING TO SUPPORT POST-YIELD ACCEPTANCE CRITERIA FOR SPENT NUCLEAR FUEL CLADDING

Spent nuclear fuel (SNF) is evaluated for structural failure during storage and transportation scenarios. The U.S. Department of Energy’s Spent Fuel and Waste Science and Technology (SFWST) program has sponsored significant research in quantifying mechanical loads on SNF during storage and transportation scenarios using experimental and modeling methods. The SFWST program has also performed significant research on measuring the mechanical behavior of irradiated SNF as defueled cladding segments and cladding with fuel pellets to measure composite behavior. This paper considers some of the key material data from the Sibling Pin testing and uses structural modeling and analysis methods that have been informed by testing to consider post-yield acceptance criteria for SNF cladding structural analysis. Test data published by Oak Ridge National Laboratory (ORNL) and Pacific Northwest National Laboratory (PNNL) are the foundation for informing the material behavior of the models developed in this study. In particular, four-point bend (4PB) tests of fueled and defueled cladding segments provide significant information about the bending failure mode of SNF. ORNL’s 4PB test data is on fueled cladding segments, so the composite behavior of SNF is demonstrated. This paper describes PNNL’s coincident beam model that was developed to approximate the composite behavior of SNF. This paper also presents PNNL’s structural dynamic finite element models of a cask tip-over scenario, which is predicted to cause the strongest mechanical loads on SNF of all postulated storage and transportation scenarios. SNF bending loads predicted in the cask tip-over scenario and cladding acceptance criteria beyond yield are considered, with justification based on the Sibling Pin test data. ASME Boiler and Pressure Vessel code stress intensity limits are also considered. The ultimate goal of this work is to aid in the justification of structural acceptance criteria for SNF cladding beyond the cladding’s irradiated yield strength for use in structural analysis of all storage and transportation scenarios.

Klymyshyn, Nicholas A.↗

NASA NTRS1972

Automated design optimization of supersonic airplane wing structures under dynamic constraints

The problems of the preliminary and first level detail design of supersonic aircraft wings are stated as mathematical programs and solved using automated optimum design techniques. The problem is approached in two phases: the first is a simplified equivalent plate model in which the envelope, planform and structural parameters are varied to produce a design, the second is a finite element model with fixed configuration in which the material distribution is varied. Constraints include flutter, aeroelastically computed stresses and deflections, natural frequency and a variety of geometric limitations.

Fox, R. L.↗

NASA NTRS1975

Coordinate transformation and truncation for rotating spacecraft with flexible appendages

The analytical structures of alternative coordinate transformations for the variables that characterize the deformations of finite element models of flexible appendages on rotating spacecraft are examined. Particular emphasis is given to the truncation operations that are essential for efficient numerical simulations of flexible spacecraft, due to the necessarily large number of coordinates employed in a finite element description. A theorem is developed which establishes necessary conditions for the commutativity of the required truncation and inversion operations. The recommended alternative for the rotating elastic appendage is a complex transformation with previously published orthogonality properties, which permit the derivation in this paper of a relatively simple explicit set of transformed and truncated equations of modal vibration in real variables.

Likins, P.↗

NASA NTRS1988

Thermal distortion analysis of the space station solar dynamic concentrator

A method was developed to evaluate the thermal distortion of the Space Station Solar Dynamic Concentrator and the effects of thermal distortion on concentrator optical performance. The analytical method includes generating temperature distributions with TRASYS and SINDA models, interfacing the SINDA results with the SINDA-NASTRAN Interface Program (SNIP), calculating thermal distortion with a NASTRAN/PATRAN finite element model, and providing flux distribution maps within the receiver with the ray tracing OFFSET program. Temperature distributions, thermally induced slope errors, and flux distribution maps within the receiver are discussed. Results during a typical orbit indicate that temperatures of the hexagonal panels and triangular facets range between -18 and 99 C (-1 to 210 F), facet rotations are less than 0.2 mrad, and a change in facet radius due to thermal flattening is less than 5 percent. The predicted power loss with thermal distortion effects was less than 0.3 percent. The thermal distortion of the Solar Dynamic concentrator has negligible effect on the flux distribution within the receiver cavity.

Trudell, Jeffrey J.↗

NASA NTRS1989

Efficient Computation Of Behavior Of Aircraft Tires

NASA technical paper discusses challenging application of computational structural mechanics to numerical simulation of responses of aircraft tires during taxing, takeoff, and landing. Presents details of three main elements of computational strategy: use of special three-field, mixed-finite-element models; use of operator splitting; and application of technique reducing substantially number of degrees of freedom. Proposed computational strategy applied to two quasi-symmetric problems: linear analysis of anisotropic tires through use of two-dimensional-shell finite elements and nonlinear analysis of orthotropic tires subjected to unsymmetric loading. Three basic types of symmetry and combinations exhibited by response of tire identified.

Tanner, John A.↗

NASA NTRS1988

Thermal distortion analysis of the Space Station solar dynamic concentrator

Trudell, Jeffery J.↗

NASA NTRS1991

Modal analysis of multistage gear systems coupled with gearbox vibrations

An analytical procedure to simulate vibrations in gear transmission systems is presented. This procedure couples the dynamics of the rotor-bearing gear system with the vibration in the gear box structure. The model synthesis method is used in solving the overall dynamics of the system, and a variable time-stepping integration scheme is used in evaluating the global transient vibration of the system. Locally each gear stage is modeled as a multimass rotor-bearing system using a discrete model. The modal characteristics are calculated using the matrix-transfer technique. The gearbox structure is represented by a finite element models, and modal parameters are solved by using NASTRAN. The rotor-gear stages are coupled through nonlinear compliance in the gear mesh while the gearbox structure is coupled through the bearing supports of the rotor system. Transient and steady state vibrations of the coupled system are examined in both time and frequency domains. A typical three-geared system is used as an example for demonstration of the developed procedure.

Choy, F. K.↗

NASA NTRS1992

Three-dimensional finite element simulation of intermingled-fiber hybrid composite behavior

Three-dimensional finite element methods and the intraply hybrid micromechanics equations are used to predict composite properties for a unidirectional graphite-epoxy primary composite with S-glass fibers used as hybridizing fibers. The micromechanics equations are embedded in a computer code ICAN (Integrated Composites Analyzer). The three-dimensional finite element model consists of three-by-three unit cell array, with a total fiber volume ratio of 0.54. There is a good agreement between the composite properties and microstresses obtained from both methods. The results indicate that the finite element methods and micromechanics equations can be used to obtain the properties of intermingled hybrid composites needed for analysis/design of hybrid composite structures.

Mital, Subodh K.↗

NASA NTRS1999

Thermal and Mechanical Performance of a Carbon/Carbon Composite Spacecraft Radiator

Carbon-carbon composite materials offer greater thermal efficiency, stiffness to weight ratio, tailorability, and dimensional stability than aluminum. These lightweight thermal materials could significantly reduce the overall costs associated with satellite thermal control and weight. However, the high cost and long lead-time for carbon-carbon manufacture have limited their widespread usage. Consequently, an informal partnership between government and industrial personnel called the Carbon-Carbon Spacecraft Radiator Partnership (CSRP) was created to foster carbon-carbon composite use for thermally and structurally demanding space radiator applications. The first CSRP flight opportunity is on the New Millennium Program (NMP) Earth Orbiter-1 (EO-1) spacecraft, scheduled for launch in late 1999. For EO-1, the CSRP designed and fabricated a Carbon-Carbon Radiator (CCR) with carbon-carbon facesheets and aluminum honeycomb core, which will also serve as a structural shear panel. While carbon-carbon is an ideal thermal candidate for spacecraft radiators, in practice there are technical challenges that may compromise performance. In this work, the thermal and mechanical performance of the EO-1 CCR is assessed by analysis and testing. Both then-nal and mechanical analyses were conducted to predict the radiator response to anticipated launch and on-orbit loads. The thermal model developed was based on thermal balance test conditions. The thermal analysis was performed using SINDA version 4.0. Structural finite element modeling and analysis were performed using SDRC/1-DEAS and UAI/NASTRAN, respectively. In addition, the CCR was subjected to flight qualification thermal/vacuum and vibration tests. The panel meets or exceeds the requirements for space flight and demonstrates promise for future satellite missions.

Kuhn, Jonathan↗

NASA NTRS2013

Parametric Thermal Soak Model for Earth Entry Vehicles

The analysis and design of an Earth Entry Vehicle (EEV) is multidisciplinary in nature, requiring the application many disciplines. An integrated tool called Multi Mission System Analysis for Planetary Entry Descent and Landing or M-SAPE is being developed as part of Entry Vehicle Technology project under In-Space Technology program. Integration of a multidisciplinary problem is a challenging task. Automation of the execution process and data transfer among disciplines can be accomplished to provide significant benefits. Thermal soak analysis and temperature predictions of various interior components of entry vehicle, including the impact foam and payload container are part of the solution that M-SAPE will offer to spacecraft designers. The present paper focuses on the thermal soak analysis of an entry vehicle design based on the Mars Sample Return entry vehicle geometry and discusses a technical approach to develop parametric models for thermal soak analysis that will be integrated into M-SAPE. One of the main objectives is to be able to identify the important parameters and to develop correlation coefficients so that, for a given trajectory, can estimate the peak payload temperature based on relevant trajectory parameters and vehicle geometry. The models are being developed for two primary thermal protection (TPS) materials: 1) carbon phenolic that was used for Galileo and Pioneer Venus probes and, 2) Phenolic Impregnated Carbon Ablator (PICA), TPS material for Mars Science Lab mission. Several representative trajectories were selected from a very large trade space to include in the thermal analysis in order to develop an effective parametric thermal soak model. The selected trajectories covered a wide range of heatload and heatflux combinations. Non-linear, fully transient, thermal finite element simulations were performed for the selected trajectories to generate the temperature histories at the interior of the vehicle. Figure 1 shows the finite element model that was used for the simulations. The results indicate that it takes several hours for the thermal energy to soak into the interior of the vehicle and achieve maximum payload temperatures. In addition, a strong correlation between the heatload and peak payload container temperature is observed that will help establishing the parametric thermal soak model.

Agrawal, Parul↗

NASA NTRS2020

DEVELOPMENT AND APPLICATION OF BENCHMARK EXAMPLES FOR MIXED-MODE I/II FATIGUE GROWTH PREDICTIONS

The development of benchmark examples for assessing growth prediction capabilities is presented and demonstrated for a commercial code. The examples are based on finite element models of Mixed-Mode Bending (MMB) specimens for three different mode ratios. The examples are independent of the analysis software used and allow the assessment of the automated delamination propagation, onset and growth prediction capabilities in commercial finite element codes based on the virtual crack closure technique (VCCT). First, based on existing results for delamination propagation under static loading, new benchmark examples for delamination growth under fatigue loading were created. Second, starting from an initially straight front, the delamination was allowed to grow under fatigue loading. The number of cycles to delamination onset and the number of cycles during delamination growth for each growth increment were obtained from the automated analysis and compared to the benchmark examples. Good agreement between the results obtained from the growth analysis and the benchmark results could be achieved by selecting the appropriate input parameters. The benchmarking procedure proved valuable by highlighting the issues associated with choosing the input parameters of the particular implementation. Overall the results from automatic propagation are encouraging, however, selecting the appropriate input parameters was not straightforward and often required an iterative procedure.

Composites↗

DOE OSTI2018

Development of Thermoacoustic Sensors for Sodium-cooled Fast Reactors

This Final Report refers to the project “Development of Thermoacoustic Sensors for Sodium-cooled Fast Reactor Systems”, which was led by Westinghouse Electric Company (Westinghouse) and carried out in collaboration with Argonne National Laboratory (ANL) and University of Pittsburgh. Thermo-acoustic Power Sensors (TAPS) are self-powered, wireless sensors envisioned for measuring key parameters, such as local temperature and neutron flux, in a nuclear reactor core. This project was intended to specifically investigate their applicability to Sodium-cooled Fast Reactors (SFR). TAPS are non-invasive (wireless) and passive (self-powered) devices. The passivity derives from their ability to use conditions that “naturally” exist in a nuclear reactor, such as gamma and neutron flux, as power sources. They generate oscillating pressure waves (i.e., sound waves) which, with a frequency and amplitude dependent upon these conditions, can travel through the core and associated structures, and reach the outside of the reactor vessel where a properly designed network of receivers can detect and interpret them. These receivers require a very small amount of power which, during loss of power events, can be provided for example by harvesting gamma radiation energy, thus resulting in a monitoring system that can function both during normal operation and during loss of power events. The project aimed at TAPS development through a series of tasks which are listed and briefly discussed as follows. TASK 1 – Sensor hardware design Subtask 1a: Assessment of sensor applications to SFRs Subtask 1b: Development of sensor functional requirements Subtask 1c: Definition of sensor hardware design specifications Task description: TAPS design was informed by considerations on their application (Subtask 1a), both the ultimate one in an SFR and the actual one in the ANL testing facilities that was intended to be used in support of the project. Considerations were made to identify optimum sensor design features that optimize the sensor size, materials, and output signal, for installation inside an SFR core. These considerations led to the development of Functional Requirements (Subtask 1b) and Design Requirements (Subtask 1c). TASK 2 – Sensor Hardware Manufacture Subtask 2a: Sensor hardware construction drawing development Subtask 2b: Sensor manufacture and assembly Task description: TAPS technical drawings were developed (Subtask 2a) using the Design Requirements established under Task 1. Subsequently, in spite of some problems which ultimately caused the program to be delayed, TAPS manufacturing was completed based on drawings (Subtask 2b). TASK 3 – Development of TAPS Signal Measurement System and TAPS Testing in Water Subtask 3a: Design, assembly and testing of signal measurement system, and TAPS testing in water Subtask 3b: Signal prediction-correction methodology development Task description: An assessment was performed on the techniques that can potentially be used to detect the signals emitted by the TAPS, e.g. a fiber-optic based acoustic signal measurement system, a laser vibrometer system, or an accelerometer-based system. The most suited technology, i.e. the accelerometer-based system, was developed further, and tested in water (Subtask 3a). Moreover, efforts were made to develop the methodology required to determine the actual system temperature and neutron flux distribution using differences between the measured and predicted TAPS responses (Subtask 3b). TASK 4 – Sensor System Testing in Sodium Subtask 4a: Test plan development Subtask 4b: Design, assembly and testing in small-scale sodium facility Subtask 4c: Design, assembly and testing in large-scale sodium and structures facility Task description: Upon proper test plan development (Subtask 4a), the fabricated TAPS was planned to be tested in sodium, by using two sodium facilities at ANL having different size and different purpose. The Under Sodium Viewing (USV) small-scale facility was intended to be used to investigate the effect of sodium on the sensor and its performance (Subtask 4b). The Mechanism Engineering Test Loop (METL) large-scale facility was instead intended to be used to assess the additional effect of prototypical SFR structures, such as fuel assembly mockup or parts of the core restrain structure, on sensor performance (Subtask 4c). As discussed in Section 3.2.2.7, unexpected issues during the TAPS manufacturing process resulted in some activities being delayed, with the TAPS and USV facility developed to the point to be ready for testing in sodium, however without the possibility to actually perform such testing (including the testing in METL) due to the end of the program’s performance period. Overall, through the development and testing (in water only) of two TAPS devices (a First-Generation TAPS followed by an optimized Second-Generation TAPS), the project confirmed the capability of this technology to generate acoustic signals proportional to temperature, which can be detected through a network of accelerometers identified as the best-suited type of receivers for acoustic signal detection. Moreover, the project also developed a computational model to predict the characteristics of the acoustic signals being generated, which combines thermal analysis of the TAPS with Finite Element Modeling (FEM)-aided acoustic characterization of the system. This model was benchmarked against experimental data collected during the project and, although general agreement was obtained, some limitations of the modeling methods were identified, which require additional development. Additional testing is needed in order to assess the effect, on TAPS operation and performance, of environmental changes resulting from the transition from water to liquid sodium. Such testing, which is suggested to be performed in the future, should look specifically at 1) both the effect resulting from the different thermoacoustic behavior of sodium (relative to water) and the effects of higher temperature on TAPS performance, and 2) the performance of the sensor-receiver system when multiple TAPS are used simultaneously and prototypical reactor structures are positioned in the testing environment. The latter testing is needed to assess the effects that potential signal attenuation/ distortion phenomena, as well as potential interference between signals emitted simultaneously, have on the performance of the technology for ultimate application in a nuclear reactor.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1992

Development of Test-Analysis Models (TAM) for correlation of dynamic test and analysis results

The primary objective of structural analysis of aerospace applications is to obtain a verified finite element model (FEM). The verified FEM can be used for loads analysis, evaluate structural modifications, or design control systems. Verification of the FEM is generally obtained as the result of correlating test and FEM models. A test analysis model (TAM) is very useful in the correlation process. A TAM is essentially a FEM reduced to the size of the test model, which attempts to preserve the dynamic characteristics of the original FEM in the analysis range of interest. Numerous methods for generating TAMs have been developed in the literature. The major emphasis of this paper is a description of the procedures necessary for creation of the TAM and the correlation of the reduced models with the FEM or the test results. Herein, three methods are discussed, namely Guyan, Improved Reduced System (IRS), and Hybrid. Also included are the procedures for performing these analyses using MSC/NASTRAN. Finally, application of the TAM process is demonstrated with an experimental test configuration of a ten bay cantilevered truss structure.

Angelucci, Filippo↗

NASA NTRS2004

Model Update of a Micro Air Vehicle (MAV) Flexible Wing Frame with Uncertainty Quantification

This paper describes a procedure to update parameters in the finite element model of a Micro Air Vehicle (MAV) to improve displacement predictions under aerodynamics loads. Because of fabrication, materials, and geometric uncertainties, a statistical approach combined with Multidisciplinary Design Optimization (MDO) is used to modify key model parameters. Static test data collected using photogrammetry are used to correlate with model predictions. Results show significant improvements in model predictions after parameters are updated; however, computed probabilities values indicate low confidence in updated values and/or model structure errors. Lessons learned in the areas of wing design, test procedures, modeling approaches with geometric nonlinearities, and uncertainties quantification are all documented.

Reaves, Mercedes C.↗

NASA NTRS2014

Aeroelastic Optimization Study Based on X-56A Model

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. Two multidisciplinary design optimization studies using an object-oriented MDAO tool developed at NASA Armstrong Flight Research Center were presented. 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. A hybrid and discretization optimization approach was implemented to improve accuracy and computational efficiency of a global optimization algorithm. The second study presents a flutter mass balancing optimization study. The results provide guidance to modify the fabricated flexible 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.

flutter constraints↗

NASA NTRS1993

Coupled structural, thermal, phase-change and electromagnetic analysis for superconductors, volume 1

This research program has dealt with the theoretical development and computer implementation of reliable and efficient methods for the analysis of coupled mechanical problems that involve the interaction of mechanical, thermal, phase-change and electromagnetic subproblems. The focus application has been the modeling of superconductivity and associated quantum-state phase-change phenomena. In support of this objective the work has addressed the following issues: (1) development of variational principles for finite elements; (2) finite element modeling of the electromagnetic problem; (3) coupling of thermal and mechanical effects; and (4) computer implementation and solution of the superconductivity transition problem. The research was carried out over the period September 1988 through March 1993. The main accomplishments have been: (1) the development of the theory of parametrized and gauged variational principles; (2) the application of those principled to the construction of electromagnetic, thermal and mechanical finite elements; and (3) the coupling of electromagnetic finite elements with thermal and superconducting effects; and (4) the first detailed finite element simulations of bulk superconductors, in particular the Meissner effect and the nature of the normal conducting boundary layer. The grant has fully supported the thesis work of one doctoral student (James Schuler, who started on January 1989 and completed on January 1993), and partly supported another thesis (Carmelo Militello, who started graduate work on January 1988 completing on August 1991). Twenty-three publications have acknowledged full or part support from this grant, with 16 having appeared in archival journals and 3 in edited books or proceedings.

Felippa, Carlos A.↗

NASA NTRS1983

An analytical investigation of shape control of large space structures by applied temperatures

An analytical procedure for the static shape control of flexible space structures subjected to thermal distortions is developed which is based on prescribing temperatures in control elements having much higher coefficients of thermal expansion than the main structure. The temperatures at the control elements are defined so as to minimize the overall thermal distortion of the structure from its ideal shape, and a matrix equation is obtained which can be solved for the set of optimum control temperatures. A formulation of the procedure for continuous structures governed by differential equations and a formulation for discrete (finite element modeled) structures governed by matrix equations are presented. The equations from the continuous formulation are employed for the shape control of a simple beam distorted by nonuniform heating, and the discrete formulation is applied in a general purpose finite-element structural analysis computer program for the shape control of a 750 m radiometer antenna reflector dish subjected to orbital heating. A reduction in thermal distortion by a factor of nearly 50 was obtained with the use of only seven control elements. Results for four different sets of control locations for the antenna are presented in which reductions in distortion of up to a factor of four were obtained.

Haftka, R. T.↗