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At least 1,225 records · Page 68

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DOE OSTI2021

TRUST-EABM Contact Thermal Conductance (CTC) Report

(U) Single Feature Testbeds to Reduce Uncertainty in Simulations and Tests [3] provided an overview for the need of experiments, with accompanying models and simulations, specifically designed to reduce uncertainties and build confidence in complex testing and analysis applications. The Contact Thermal Conductance (CTC) testbed is a joint effort between W-13 (formerly E-13) and MST-8. The objective of this study was to design a testbed, with accompanying finite element models, to quantify, reduce, and propagate measurement uncertainties in contact thermal conductance measurements between two mating components in WR-like thermal environments. The knowledge gained through this simplified experiment would educate more complex assessments and interaction conditions with WR-like materials and geometries.

42 ENGINEERING↗

NASA NTRS1982

Stress analysis and design considerations for Shuttle pointed autonomous research tool for astronomy /SPARTAN/

The Shuttle Pointed Autonomous Research Tool for Astronomy (SPARTAN) family of spacecraft are intended to operate with minimum interfaces with the U.S. Space Shuttle in order to increase flight opportunities. The SPARTAN I Spacecraft was designed to enhance structural capabilities and increase reliability. The approach followed results from work experience which evolved from sounding rocket projects. Structural models were developed to do the analyses necessary to satisfy safety requirements for Shuttle hardware. A loads analysis must also be performed. Stress analysis calculations will be performed on the main structural elements and subcomponents. Attention is given to design considerations and program definition, the schematic representation of a finite element model used for SPARTAN I spacecraft, details of loads analysis, the stress analysis, and fracture mechanics plan implications.

Ferragut, N. J.↗

NASA NTRS1998

Residual Stresses Modeled in Thermal Barrier Coatings

Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We examined the effect on stress during burner rig thermal cycling of the following independent variables: creep in the bond coat and top coat, oxidation, bond coat coefficient of thermal expansion, number of thermal cycles, and interfacial roughness. All these factors were suspected of influencing TBC failure. The model showed that all the material properties studied had a significant effect on the coating's residual stresses if the interface of the bond coat was rough. Bond coat expansion, bond coat oxidation, and bond coat creep had the highest effect on coating stresses, and these were highly interactive. The model also showed that the mechanism of stress generation during thermal cycling changed with the number of thermal cycles. Bond coat and top coat creep dominated stress generation during early thermal cycles, greatly increasing delamination stresses at the peaks of the bond coat. Therefore, creep is the prime driver for delamination cracking early in life, but cracking is limited to the bond coat peak region. Oxidation of the bond coat, on the other hand, tended to dominate stress generation during later cycles by greatly increasing delamination stresses over bond coat valleys. These results indicate that oxidation is the driver for the continued cracking necessary to cause ceramic layer spallation.

Freborg, A. M.↗

NASA NTRS2008

Analysis of Bonded Joints Between the Facesheet and Flange of Corrugated Composite Panels

This paper outlines a method for the stress analysis of bonded composite corrugated panel facesheet to flange joints. The method relies on the existing HyperSizer Joints software, which analyzes the bonded joint, along with a beam analogy model that provides the necessary boundary loading conditions to the joint analysis. The method is capable of predicting the full multiaxial stress and strain fields within the flange to facesheet joint and thus can determine ply-level margins and evaluate delamination. Results comparing the method to NASTRAN finite element model stress fields are provided illustrating the accuracy of the method.

Yarrington, Phillip W.↗

NASA NTRS2012

SOFIA: Flying the Telescope

The primary focus of this paper is how the flight test team for the Stratospheric Observatory For Infrared Astronomy (SOFIA) re-cast an extensive developmental test program to meet key milestones while simultaneously ensuring safe certification of the airframe and delivery of an operationally relevant platform, ultimately saving the overall program from financial demise. Following a brief introduction to the observatory and what it is designed to do, SOFIAs planned developmental test program is summarized, including analysis and design philosophy, envelope expansion, model validation and airframe certification. How NASA used lessons learned from other aircraft that employed open cavities in flight is explained as well as how and why the chosen design was selected. The approach to aerodynamic analysis, including bare airframe testing, wind tunnel testing, computational fluid dynamics and finite element modeling proved absolutely critical. Despite a solid analytical foundation, many unknowns remained. History provides several examples of disastrous effects on both systems and flight safety if cavity design is not approached properly. For these reasons, an extensive test plan was developed to ensure a safe and thorough build-up for envelope expansion, airframe certification and early science missions. Unfortunately, as is often the case, because of chronic delays in overall program execution, severe schedule and funding pressures were present. If critical milestones were not met, domestic as well as international funding was in serious jeopardy, and the demise of the entire program loomed large. Concentrating on rigorous model validation, the test team challenged certification requirements, increased test efficiency and streamlined engineering analysis. This resulted in the safe reduction of test point count by 72%, meeting all program milestones and a platform that soundly satisfied all operational science requirements. Results from early science missions are shown and a proof of concept mission for which SOFIA was opportunely positioned is showcased. Success on this time-critical mission to observe a rare astronomical event proved the usefulness of an airborne observatory and the value in waiting for the capability provided by SOFIA. Finally, lessons learned in the test program are presented with emphasis on how lessons from previous aircraft and successful test programs were applied to SOFIA. Effective application of these lessons was crucial to the success of the SOFIA flight test program. SOFIA is an international cooperative program between NASA and the German Space Agency, DLR. It is a 2.5 meter (100-inch) telescope mounted in a Boeing 747SP aircraft used for astronomical observations at altitudes above 35,000 feet. SOFIA will accommodate a host of scientific instruments from the international science community and has a planned operational lifespan of more than 20 years.

Asher, Troy A.↗

DOE OSTI2024

Transient Chemo‐Mechanical Model of Lithium Plating Impacted by External Pressure

Abstract Lithium anodes show great promise in commercial applications, but are hindered by lithium plating and dendrite growth which cause safety concerns during long‐term cell operation. Stack pressure is experimentally observed to improve cell lifetime; however, the relationship between stress and lithium deposition has remained difficult to elucidate. In this work, a transient, 3D, finite‐element model of the evolution of a lithium anode due to stripping and plating is developed. The evolution of a microscale protrusion on the anode surface is tracked over one charge‐discharge cycle with respect to stack pressure and lithium yield strength. Lithium plastic deformation, nonconformal anode‐separator contact, and separator porosity effects are accounted for. Over the course of several hours of stripping/plating, the anode surface evolves to a similar morphology under pressure regardless of the initial conditions due to lithium plastic deformation and hardening. The rate of this evolution highly depends on the applied pressure and assumed lithium yield strength.

25 ENERGY STORAGE↗

DOE OSTI2021

Determining failure properties of as-received and hydrided unirradiated Zircaloy-4 from ring compression tests

An integrated experimental and computational approach was developed to determine the plastic strain at fracture and to investigate the fracture energy of as-received and hydrided unirradiated Zircaloy-4 nuclear cladding tubes in the hoop direction at room temperature from ring compression testing (RCT). This work builds on previous methods in the literature that were developed to obtain the mechanical properties of nuclear cladding before fracture (Young’s modulus, yield stress, and strain-hardening parameters) from experimental RCT results and extends the characterization of this material class to include material failure properties. Furthermore, a ductile damage approach was developed and implemented in a validated finite element model to predict material failure, evaluate fracture energy, and quantify the plastic strain at fracture initiation. The hydrogen content of the Zircaloy-4 specimens was varied up to 610 wppm when the failure became brittle. As expected, increasing hydrogen content caused embrittlement of the Zircaloy-4 samples tested and the plastic strain at fracture and fracture energy to decrease.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Computationally efficient models for aqueous organic redox flow batteries

The rising usage of intermittent energy has garnered the need for large scale energy storage systems. Redox flow batteries (RFB) based energy storage system shows promising potential. Numerical simulations and machine learning approaches have been widely used to study RFB performance. The development of autonomous material discovery framework and digital twin of energy storage system usually needs to query cell performance through fast response models. In this study, two computationally efficient models are introduced: a physics-based analytical flow battery model (EZBattery), and a machine learning operator model (Deep Operator Network, denoted by DeepONet). Both models can provide cell performance near instantly, and prediction accuracy was systematically examined on an application of evaluating the performances of a 780 cm 2 aqueous organic redox flow battery (AORFB), using potential anolyte candidates in dihydroxyphenazine (DHP)-based family of organic materials. A validated computationally expansive 3-dimensional multi-physics finite element model by COMSOL was used as the ground truth and provided the training data set for the DeepONet. 1280 samples were generated with 10 properties to mimic the different possible anolyte candidates, and the cell performances were evaluated under 10 different combined operating conditions. The accuracy comparisons for the two computationally efficient models show that both models can provide comparable accuracy in predicting cell charging/discharging voltage curves. DeepONet can provide slightly higher overall accuracy than EZBattery with faster calculation speed, but highly relies on the training dataset. EZBattery does not need a training dataset and can provide interpretable physics-based explanations of the results, while being more flexible to adjust to adapt any different cell designs, flow battery architectures, and electrolyte materials.

Analytical model↗

DOE OSTI2025

Grain2Mesh: Mesh Generation for Grain-Scale Nonlinear Elasticity Modeling

The nonlinear hysteretic behavior of rocks under cyclic loading is a crucial area of study in geomechanics. The macroscopic response of a variety of materials has been found to be contingent upon the behavior of the micro-scale structure. This project aims to develop a functional and maintainable software package for generating a multi-phase numerical mesh and accompanying simulation files for finite element modeling used in computational mechanics solvers. Meshes generated from images often lack key preprocessing that reduces noise and prevents mesh element distortion that can increase computational cost. By incorporating user feedback throughout, grain2mesh ensures a high-fidelity mesh that can be used to model grain-scale interactions such as shearing, crack propagation, and interfacial material contrast. Scientific applications of this software include material fracturing, stress-strain analysis for natural and engineered materials, and nonlinear meso-scale analysis.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1993

Damage detection using experimentally measured mass and stiffness matrices

A method is presented for locating physical damage or change in a structure using experimentally measured mass and stiffness matrices. The approach uses a recently developed algorithm for transforming a state-space realization into a second order structural model with physical displacements as the generalized coordinates. This is accomplished by first rotating a state-space model of the identified structural dynamics into modal coordinates and approximating the mass normalized modal vectors for the output measurement set. Next, the physical mass, damping and stiffness matrices are synthesized directly from the measured modal parameters. This yields experimental mass and stiffness matrices for the structure without the use of a finite element model or a numerical search. The computed mass and stiffness are asymptotically equivalent to a static condensation of the global physical coordinate model. Techniques for solving the inverse connectivity problem are then developed whereby it is possible to assess the stiffness in a region of the structure bounded by several sensors. Applications to both simulated data and experimental data are used to discuss the effectiveness of the approach.

Peterson, L. D.↗

NASA NTRS2023

Thermomechanical Real-Time Hybrid Simulation: Conceptual Framework and Control Requirements

Real-time hybrid simulation (RTHS) is an enabling technology that has transformed engineering experimentation and helped researchers expand modeling capabilities. However, breakthroughs are necessary to expand the range of hybrid simulation methods and, thus, enable experiments with loading conditions representing multiple hazards. This paper discusses the development of a new thermomechanical RTHS framework and a systematic approach to determining RTHS control requirements. First, the framework is established using a representative finite element model of a layered structural system subjected to thermal loading. A complete two-layer system model serves as the reference system, and it is then partitioned into a numerical layer and an experimental layer that share interface conditions. Next, a thermal actuator is introduced to impose dynamic thermal loading on the experimental subsystem, serving as a transfer system. Finally, control and performance metrics are defined to evaluate the realization of interface boundary conditions and map this to the RTHS execution. Through an illustrative example considering the influence of temperature on a lunar habitat, we demonstrate how to establish controller requirements for RTHS and demonstrate that this approach can be used to conduct RTHS on structures with thermomechanical loading.

Herta Montoya↗

NASA NTRSDate not supplied

Applicability of Loads Estimation Techniques Using Sparse Acceleration Sensor Data to Spacecraft Structural Health Monitoring

The use of structural health monitoring systems on spacecraft structures can play a crucial role in ensuring the safety, reliability, and longevity of the structure by gathering and analyzing onboard sensor data. Of specific importance is monitoring for excessive loading at critical interfaces as any off-nominal structural excitations experienced by spacecraft structures can cause early unpredicted high structural life consumption or damage. The availability and cost of flight-certified sensors along with the size of spacecraft structures and allowable payload mass drives the need for a method to estimate loads using sparsely-located sensors. Numerous approaches such as physics-based, statistical learning, and physics-enhanced statistical learning algorithms have gained popularity among structural prognostics applications. However, developing noise-robust prediction models to assess loads and structural life predictions from a sparse multi-sensor data acquisition system can be a challenging task. This paper discusses the evaluation of physics-based versus machine-learning algorithms for predicting loads and structural life at mission critical locations on the spacecraft structure using a finite element loads analysis with the application of simulated noise and noise reduction techniques. To estimate the loads from accelerations, the physics-based algorithm leverages a loads transformation matrix from a Craig-Bampton reduced finite element model. A System Equivalent Reduction Expansion Process (SEREP) and a pseudo-inverse approach are considered to expand from the onboard sensor degrees of freedom to the Craig-Bampton model degrees of freedom. The machine learning algorithm provides a data driven solution/mapping of the sensor accelerations to the loads at the mission critical locations using a high dimensionality analysis. Although these strategies produce comparable loads prediction without noise, the limitations of these strategies with incorporating simulated noise and noise reduction techniques with low signal to noise ratio signals are evaluated. The study demonstrates the immense potential of statistical learning algorithms for sparse structural prognostic models and enhancing signal denoising techniques. These findings also highlight the need for noise-resilient prognostic models and low-noise data acquisition systems onboard spacecraft structures.

Spacecraft Structural Health Monitoring↗

NASA NTRS1992

Modal Test/Analysis Correlation of Space Station Structures Using Nonlinear Sensitivity

The modal correlation problem is formulated as a constrained optimization problem for validation of finite element models (FEM's). For large-scale structural applications, a pragmatic procedure for substructuring, model verification, and system integration is described to achieve effective modal correlation. The space station substructure FEM's are reduced using Lanczos vectors and integrated into a system FEM using Craig-Bampton component modal synthesis. The optimization code is interfaced with MSC/NASTRAN to solve the problem of modal test/analysis correlation; that is, the problem of validating FEM's for launch and on-orbit coupled loads analysis against experimentally observed frequencies and mode shapes. An iterative perturbation algorithm is derived and implemented to update nonlinear sensitivity (derivatives of eigenvalues and eigenvectors) during optimizer iterations, which reduced the number of finite element analyses.

Gupta, Viney K.↗

NASA NTRS1992

Modal test/analysis correlation of Space Station structures using nonlinear sensitivity

The modal correlation problem is formulated as a constrained optimization problem for validation of finite element models (FEM's). For large-scale structural applications, a pragmatic procedure for substructuring, model verification, and system integration is described to achieve effective modal correlations. The space station substructure FEM's are reduced using Lanczos vectors and integrated into a system FEM using Craig-Bampton component modal synthesis. The optimization code is interfaced with MSC/NASTRAN to solve the problem of modal test/analysis correlation; that is, the problem of validating FEM's for launch and on-orbit coupled loads analysis against experimentally observed frequencies and mode shapes. An iterative perturbation algorithm is derived and implemented to update nonlinear sensitivity (derivatives of eigenvalues and eigenvectors) during optimizer iterations, which reduced the number of finite element analyses.

Gupta, Viney K.↗

NASA NTRS1985

Modeling of elastically mounted vertical rotor

The evaluation of the dynamic behavior of a rotating system is possible by means of modal parameters (Eigenvalues and Eigenvectors). A mixed analytical and experimetal approach is used to identify the modal parameters of a specially designed test rig. The modal identification is done both for nonrotating as well as rotating systems. These modal parameters are used to validate a developed Finite Element Model.

Dana, S. S.↗

NASA NTRS2018

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗

NASA NTRS2017

Single Degree-of-Freedom Modeling of SLS Liquid Hydrogen Pre-Valve Flow Guide to Enable Rapid Transient Analysis

A unique single degree-of-freedom approximation technique has been developed to enable rapid application of a temporally-defined multi-spectral semi-narrow-band loading for generation of realistic stress/cycle values compared to a resonant analysis. The technique uses the harmonic analysis at resonance of a high-fidelity finite element model to produce a transfer function, which is then used to calibrate the response of the SDOF model. A standard numerical ordinary differential equation solver is then used to obtain the temporal response, and its histogram is used in a fatigue/fracture model. This technique is related to other SDOF methods used widely in industry, such as Miles' Equation and the Shock Response Spectra, but it is unique in that it produces a realistic time history of the response. The most obvious error in the process, which is the effect of closely-spaced modes, was also assessed using the parallel application of several SDOF models, and the error is shown to be small. The application of this unique and tractable reduced-order methodology has enabled the SLS program to avoid substantial cost and schedule penalties if a redesign or change of material were required. It has also enabled quick analysis of a number of other structures undergoing the same or similar excitation fields, and quick assessment when the excitation and structural configuration has been altered due to design changes in the system.

Brown, Andrew M.↗

DOE OSTI2021

Evaluation of Structural Lattices for a Davis Gun Earth Penetrator Impact Experiment

The advanced materials team investigated the use of additively manufactured metallic lattice structures for mitigating impact response in a Davis gun earth penetrator impact experiment. High-fidelity finite element models were developed and validated with quasistatic experiments. These models were then used to simulate the response of such lattices when subjected to the acceleration loads expected in the Davis gun experiment. Results reveal how the impact mitigation performance of lattices can change drastically at a certain relative density. Based on these observations, an experiment deck was designed to probe the response of lattices with different relative densities during the Davis gun phase 2 shots. The expected performance of these lattices is predicted before testing based on simulation results. The results of the Davis gun phase 2 shots are expected to provide data which will be used to assess the predictive capability of the finite element simulations in such a complex impact environment.

36 MATERIALS SCIENCE↗