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DOE OSTI2018

Material Model Testing in the DYNA3D Code: Material Models 1 through 5

This report is the first volume in an effort to study the material model implementations in DYNA3D, using the latest developmental version of the code. Input files were derived from a template supplied by Jerry Lin to perform an equation-of-state study. Most of the simulations use 10 cubes, each 1 cm on a side with a density of 8.03 (steel). Each of the cubes tests a different aspect of the material model. The first three cubes are testing normal stresses and normal strains (uniaxial stresses and strains) placed on the cube parallel to the x-axis, y-axis and z-axis, respectively. The x (or y or z) = 1 face of the cube is moved along the x-axis (or y-axis or z-axis) to test the model, while the opposite side remains in the x (or y or z) = 0 plane. For some of the tests, the nodes are free to move perpendicular to the applied strain to allow the cross-sectional area of the cube to change in response to being placed under pressure or tension (to test Poisson’s Ratio), while in others the nodes are frozen to eliminate dynamic effects resulting from the code. The cube is placed in tension along the axis being tested and then released, followed by a cycle of compression and release. This tension/compression cycle is repeated 3 more times. The additional cycles allow for the model to be tested under different loads. For these calculations, the amount by which the cube is stretched and compressed is varied from cycle to cycle to allow testing of model features. Cubes number 4 and 5 are intended to test xy shear stresses/strains. This is done by sliding one face of the cube in its plane parallel to the axis of interest. For example, for cube 4, the upper face of the cube is slid in the y=1 plane in a direction parallel to the x-axis (so there are no changes in the y and z coordinates of the points in the plane) and then returned to its starting position. This preserves the volume of the cube, so there is no change in density or pressure. The cycle is repeated 8 times. For cube 5, the plane of the cube satisfying x=1 is slid in this plane in a direction parallel to the y-axis and then returned to its starting position. This preserves the volume of the cube, so there is no change in density or pressure. The cycle is repeated 8 times. Cubes number 6 through 9 repeat these tests for yz shear stresses/strains (Cubes 6 and 7) and zx shear stresses and strains (Cubes 8 and 9). For reasons discussed in the next paragraph, it is unclear if these tests represent a state of pure shear stress and shear strain in the code. Application of shear stresses and strains should not, in general, result in the appearance of normal stresses and strains in Cubes 4 - 9. In the infinitesimal limit, this result might be obtained. However, DYNA3D is a finite deformation code and in the real deformations used in the code, this result is not achieved and the individual components of the normal stresses and strains are non-zero during the cycling. However, the sums of the normal strains are zero in these tests and, except in the case of thermally dependent models, so are the sums of the normal stresses. Cube 10 tests the response of the material model to a hydrostatic loading of the cube. The load curve used for the first three tests is used again and applied to each of the 8 nodes in a manner causing the cube to be either compressed or expanded. This compression/tension cycle is repeated 4 times. The additional cycles allow for the model to be tested under different loads. The amount by which the cube is stretched and compressed is varied from cycle to cycle to allow testing of model features. This document will discuss the testing of Material Models 1 through 5. Relevant results from the test cubes will be discussed. A discussion of the results from all 10 test cubes will be presented only if necessary.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Compressible Arch Segments for the Cigeo Access Ramps, Drifts and Vaults - A Field Test - 17011

Andra is currently implementing the detailed engineering phase of the step-wise design development of Cigeo (the French HLW and IL-LLW Deep Geological Repository). Various technical issues are at stake, including the requirements linked to 'Reversibility / Retrievability', at different stages of the repository life cycle (from its construction start-up to its final closure and monitoring). These reversibility requirements have a significant impact on the way Cigeo is designed, will be progressively developed, operated, later closed and monitored. On a shorter term, one must demonstrate that the waste container retrieval operations are technically safe and feasible. In that sense, the structural dimensioning of the ramps and mains, as well as that of the IL-LLW disposal vaults, is critical, since the concrete liner supporting the rock walls must last over a period of some 100 to 150 years (lapse of time during which retrieval operations are likely to take place). The present paper starts with a description of the geomechanical conditions prevailing in the Callovo-Oxfordian (COX) clay-stone formation (aka the argillite). The structural dimensioning of the IL-LLW disposal vault liner, as calculated at the end of the basic engineering phase is indicated. The thickness values obtained so far have led to considering an alternative design in which a compressible material is positioned between the concrete liner intrados and the rock walls: in such situation, the 'creeping effect' of the rock is mitigated, for a time, by the compressible material (nearly a perfect elastoplastic material), hence reducing the stress level exerted inside the concrete liner. This situation enables to significantly reduce the liner thickness and provides potentially significant saving in the construction of the works concerned (preliminary sensitivity results are given). The following part of the paper is then focused on a practical case story: a technological demonstration (still ongoing) of a tunnel boring experiment, implemented underground (in a dedicated drift of the Meuse Haute Marne URL infrastructures, at scale 1:2 of the Cigeo drifts/vaults). In this excavation and construction experiment, the tunnel boring machine (TBM) lays (via an erector) 'classical' concrete arch segments (forming a ring) in a first portion of the drift and 'compressible' ones (the compressible material is positioned on their extrados) in a second portion of the drift. The technical demonstration objective is two-fold: the capacity to lay compressible arch segments with a TBM is checked, their structural behavior (with time) is compared with that of 'classical' ones. The way the compressible material is produced and then fixed on the arch concrete segment is also documented, c/w a description of the complementary testing campaign to be carried out on a test bench (on surface) of a concrete ring (at a scale 1:2 of Cigeo) formed of compressible arch segments. This paper concludes with a timeline of the experiment. Should the results obtained provide some perspectives of technical and economic improvement (i.e. saving vis-a-vis the 'classical' solution) a decision could be taken by Andra to incorporate this alternative solution in the 'design freeze' of Cigeo underground infrastructures. The positive outcomes of this technical test campaign would also pave the way for specifying the Cigeo TBM characteristics (dimensions and handling equipment), scheduled for manufacturing order around 2020. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1975

Reliability aspects of a composite bolted scarf joint

The design, fabrication, static test, and fatigue test of both tension and compression graphite-epoxy candidates for a wing splice representative of a next-generation transport aircraft was the objective of the reported research program. A single-scarf bolted joint was selected as the design concept. Test specimens were designed and fabricated to represent an upper-surface and a lower-surface panel containing the splice. The load spectrum was a flight-by-flight random-load history including ground-air-ground loads. The results of the fatigue testing indicate that, for this type of joint, the inherent fatigue resistance of the laminate is reflected in the joint behavior and, consequently, the rate of damage accumulation is very slow under realistic fatigue loadings.

Reed, D. L.↗

NASA NTRS1990

Open hole and post-impact compression fatigue of stitched and unstitched carbon/epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, M. A.↗

NASA NTRS1992

Open hole and postimpact compressive fatigue of stitched and unstitched carbon-epoxy composites

Portanova, Marc A.↗

DOE OSTI2019

Material Property Determinations of P-Tunnel Core in Support of UNESE

A critical component of the Underground Nuclear Explosion Signatures Experiment (UNESE) program is a realistic understanding of the post-detonation processes and changes in the environment that produce observable physical and radio-chemical signatures. Rock and fracture properties are essential parameters for modeling underground nuclear explosions. In response to the need for accurate simulations of physical and radio-chemical signatures, an experimental program to determine porosity, hydrostatic and triaxial compression, and Brazilian disc tension properties of P-Tunnel core was developed and executed. This report presents the results from the experimental program. Dry porosity for P-Tunnel core ranged from 8.7%-55%. Based on hydrostatic testing, bulk modulus was shown to increase with increasing confining pressure and ranged from 1.3GPa-42.3GPa. Compressional failure envelopes, derived from wet samples, are presented for P-Tunnel lithologies. Brazilian disc tension tests were conducted on wet samples and, along with triaxial tests, are compared with dry tests from the first UNESE test bed, Barnwell. P-Tunnel core disc tension test strength varied nearly two orders of magnitude between lithologies (0.03MPa-2.77MPa). Material tested in both tension and compression is weaker wet than dry with the exception of Strongly Welded Tuff in compression which is nearly identical in compressive strength for confining pressures of OMPa and 1 OOMPa. In addition to the inherent material properties of the rocks, fractures within the samples were quantified and characterized, in order to identify differences that might be caused by the explosion-induced damage. Finally, material property determinations are linked to optical microscopy observations. The work presented here is part of a broader material characterization effort; reports are referenced within.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2017

A convenient miniature test platform for polyelectrolyte membrane fuel-cell research

We report a simple and convenient small-scale fuel-cell test platform was created from a commercial compression fitting and graphite rod current collectors and used to conduct diagnostic tests on disk-shaped membrane-electrode assemblies (MEAs) fabricated from Nafion membranes and Nafion-impregnated platinum-on-carbon-cloth anodes and cathodes. A key advantage of this test platform is that it requires very little material, perhaps just a few milligrams, to conduct a fuel-cell test on a supported catalyst. Electrochemically-active surface area (ECSA) values for supported platinum on carbon-cloth electrodes were obtained by in-situ (in the fuel cell) and ex-situ (in liquid electrolyte) cyclic voltammetry on similarly-prepared electrodes, and values obtained by these methods were compared with each other to estimate the fraction of platinum catalyst contacted by the Nafion ionomer in the fuel-cell cathode. Polarization curves were acquired under controlled-potential conditions using slow-scan cyclic and sampled-current voltammetry and potential-step amperometry methods with conventional electroanalytical instrumentation. Tests performed using this platform are complementary to rotating disk electrode (RDE) voltammetry tests which also allow for catalyst testing on small amounts of material, albeit in the presence of liquid electrolyte, and are commonly used for initial screening of new fuel-cell catalysts. They are also complementary to conventional fuel-cell testing that is commonly performed on MEAs having active areas more than 100 times larger than that in the present cells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1996

Control of Flow Separation Using Adaptive Airfoils

A novel way of controlling flow separation is reported. The approach involves using an adaptive airfoil geometry that changes its leading edge shape to adjust to the instantaneous flow at high angles of attack such that the flow over it remains attached. In particular, a baseline NACA 0012 airfoil, whose leading edge curvature could be changed dynamically by 400% was tested under quasi-steady compressible flow conditions. A mechanical drive system was used to produce a rounded leading edge to reduce the strong local flow acceleration around its nose and thus reduce the strong adverse pressure gradient that follows such a rapid acceleration. Tests in steady flow showed that at M = 0.3, the flow separated at about 14 deg. angle of attack for the NACA 0012 profile but could be kept attached up to an angle of about 18 deg by changing the nose curvature. No significant hysteresis effects were observed; the flow could be made to reattach from its separated state at high angles by changing the leading edge curvature. Interestingly, the flow over a nearly semicircular nosed airfoil was separated even at low angles.

Chandrasekhara, M. S.↗

NASA NTRS1996

Control of Flow Separation Using Adaptive Airfoils

Chandrasekhara, M. S.↗

NASA NTRS1992

Experimental testing of prototype face gears for helicopter transmissions

An experimental program to test the feasibility of using face gears in a high-speed and high-power environment was conducted. Four face gear sets were tested, two sets at a time, in a closed-loop test stand at pinion rotational speeds to 19,100 rpm and to 271 kW. The test gear sets were one-half scale of the helicopter design gear set. Testing the gears at one-eighth power, the test gear set had slightly increased bending and compressive stresses when compared to the full scale design. The tests were performed in the LeRC spiral bevel gear test facility. All four sets of gears successfully ran at 100 percent of design torque and speed for 30 million pinion cycles, and two sets successfully ran at 200 percent of torque for an additional 30 million pinion cycles. The results, although limited, demonstrated the feasibility of using face gears for high-speed, high-load applications.

Handschuh, R.↗

NASA NTRS1931

Performance of a Compression-ignition Engine with a Precombustion Chamber Having High-Velocity Air Flow

Presented here are the results of performance tests made with a single-cylinder, four stroke cycle, compression-ignition engine. These tests were made on a precombustion chamber type of cylinder head designed to have air velocity and tangential air flow in both the chamber and cylinder. The performance was investigated for variable load and engine speed, type of fuel spray, valve opening pressure, injection period and, for the spherical chamber, position of the injection spray relative to the air flow. The pressure variations between the pear-shaped precombustion chamber and the cylinder for motoring and full load conditions were determined with a Farnboro electric indicator. The combustion chamber designs tested gave good mixing of a single compact fuel spray with the air, but did not control the ensuing combustion sufficiently. Relative to each other, the velocity of air flow was too high, the spray dispersion by injection too great, and the metering effect of the cylinder head passage insufficient. The correct relation of these factors is of the utmost importance for engine performance.

Spanogle, J A↗

DOE OSTI2015

Mesoscale Phase Field Modeling of Glass Strengthening Under Triaxial Compression

Recent hydraulic bomb and confined sleeve tests on transparent armor glass materials such as borosilicate glass and soda-lime glass showed that the glass strength was a function of confinement pressure. The measured stress-strain relation is not a straight line as most brittle materials behave under little or no confinement. Moreover, borosilicate glass exhibited a stronger compressive strength when compared to soda-lime glass, even though soda-lime has higher bulk and shear moduli as well as apparent yield strength. To better understand these experimental findings, a mesoscale phase field model is developed to simulate the nonlinear stress versus strain behaviors under confinement by considering heterogeneity formation under triaxial compression and the energy barrier of a micro shear banding event (referred to as pseudo-slip hereafter) in the amorphous glass. With calibrated modeling parameters, the simulation results demonstrate that the developed phase field model can quantitatively predict the pressure-dependent strength, and it can also explain the difference between the two types of glasses from the perspective of energy barrier associated with a pseudo-slip event.

Confined Borosilicate↗

DOE OSTI2015

Impact of Effective Compression Ratio on Gasoline-Diesel Dual-Fuel Combustion in a Heavy-Duty Engine Using Variable Valve Actuation

Dual-fuel combustion using port-injected gasoline with a direct diesel injection has been shown to achieve low-temperature combustion with moderate peak pressure rise rates, low engine-out soot and NOx emissions, and high indicated thermal efficiency. A key requirement for extending high-load operation is moderating the reactivity of the premixed charge prior to the diesel injection. Reducing compression ratio, in conjunction with a higher expansion ratio using alternative valve timings, decreases compressed charge reactivity while maintain a high expansion ratio for maximum work extraction. Experimental testing was conducted on a 13L multi-cylinder heavy-duty diesel engine modified to operate dual-fuel combustion with port gasoline injection to supplement the direct diesel injection. The engine employs intake variable valve actuation (VVA) for early (EIVC) or late (LIVC) intake valve closing to yield reduced effective compression ratio. Testing was conducted at a mid-load operating condition using a gasoline-diesel dual-fuel operating strategy. The impact on dual-fuel engine performance and emissions with respect to varying effective compression ratio is quantified within this study. As effective compression ratio is reduced, overall massflow through the engine decreases, yielding both higher gas exchange efficiencies and increased heat transfer losses. With constant combustion phasing gasoline/diesel fueling fraction, and NOx emissions held constant, overall brake thermal efficiency remains relatively constant across effective compression ratios.

Ickes, Andrew↗

NASA NTRS1992

Compressive residual strength of graphite/epoxy laminates after impact

The issue of damage tolerance after impact, in terms of the compressive residual strength, was experimentally examined in graphite/epoxy laminates using Hercules AS4/3501-6 in a (+ or - 45/0)(sub 2S) configuration. Three different impactor masses were used at various velocities and the resultant damage measured via a number of nondestructive and destructive techniques. Specimens were then tested to failure under uniaxial compression. The results clearly show that a minimum compressive residual strength exists which is below the open hole strength for a hole of the same diameter as the impactor. Increases in velocity beyond the point of minimum strength cause a difference in the damage produced and cause a resultant increase in the compressive residual strength which asymptotes to the open hole strength value. Furthermore, the results show that this minimum compressive residual strength value is independent of the impactor mass used and is only dependent upon the damage present in the impacted specimen which is the same for the three impactor mass cases. A full 3-D representation of the damage is obtained through the various techniques. Only this 3-D representation can properly characterize the damage state that causes the resultant residual strength. Assessment of the state-of-the-art in predictive analysis capabilities shows a need to further develop techniques based on the 3-D damage state that exists. In addition, the need for damage 'metrics' is clearly indicated.

Guy, Teresa A.↗

NASA NTRS1998

Phenylethynyl Containing Polyarylene Ethers/Polyimides Resin Infiltration of Composites

The following tasks were performed at NCA&TSU during the second year in performance of the grant. LaRC-LV-1 13 resin was synthesized at NCA&TSU. In order to perform the synthesis, glassware and needed apparatus were purchased with grant funds along with the appropriate monomers. It was found that the LaRC-LV-1 13 resin was easily synthesized by the NMP solvent/toluene imminization/distilled water precipitation process. However, in use this resin exhibited a bubbling/foaming behavior during cure that was detrimental leading to the production of composite panels having a high void content. Composite panels were fabricated using compression molding and resin transfer molding (RTM) techniques. Initial fiber volume determinations were computed at NCA&TSU along with NASA-Langley measured c-scans on the panels produced. The initial results indicated a unsatisfactory level of approximately 20% by volume of voids. Testing of uniaxial coupons in compression to failure also agreed with these results. The uniaxial coupons delaminated as the major mode of failure indicative of an unacceptably low level of resin and to much void content in the final composites produced. In discussions with Dr. Brian Jensen, it was suggested the void fraction needs to be reduced to at least 2% by volume for a useful composite. The panels produced used both resin synthesized at NASA-Langley and NCA&TSU. In reviewing our progress over the past year, it was noted that the resin as formulated by the current synthesis process bubbled at elevated temperature. This was especially observed in neat resin slugs cured at the recommended one, four and eight hour cure temperatures. Pressurized cures where then performed with pressures up to 200 psi and simultaneously the lowest eight hour cure temperatures. Although this procedure reduced the amount of bubbles to some extent in the neat resin slugs it did not completely eliminate them. The cure reaction appears to be very energetic even at the lowest recommended cure temperature. Currently, the pressurized cure apparatus developed at NCA&TSU is limited to 200 psi.

Dunn, DeRome O.↗

NASA NTRS2017

Juno Gravity Science: Preparing for Data Collection at Jupiter

One of the primary goals of the Juno mission is to investigate Jupiter’s interior by mapping its gravitational field with the gravity science instrument. The Juno spacecraft has two radio science components that comprise the gravity science instrument: the X-band telecommunications system for a X-up/X-down link and a Ka-band Translator for a Ka-up/Ka-down link. The Deep Space Network’s DSS-25 beam waveguide antenna at the Goldstone Deep Space Communications Complex in California provides the X- and Ka-band uplink alongside an Advanced Water Vapor Radiometer to calibrate tropospheric effects. X-band and Ka-band downlink data are collected with both open-loop and closed-loop receivers located at the complex. Utilization of Ka-band provides scientific benefit to the Doppler measurements, but also adds operational challenges. Pointing of the uplink and downlink Ka-band signals requires additional systems to be calibrated and operated by the Deep Space Network; and the higher frequency of Ka-band means the signal dynamics are increased by a factor of four over X-band signals. Due to the spacecraft’s elliptical orbit and 4000 kilometer perijove altitude, it accelerates at an extreme rate as it approaches Jupiter, inducing large dynamic ranges in Doppler range of approximately 6 MHz over 3 hours at Ka-band. After the installation of a new Ka-band transmitter at DSS-25 for Juno was completed in 2015, end-to-end testing was conducted to ensure readiness for operations at Jupiter and provide an initial assessment of the performance. Cruise testing was conducted in the same operational configuration that the system will be used in during perijove passes. Processed open-loop data yielded uncalibrated Doppler residuals of 1.9 mHz at X-band and 6.0 mHz at Ka-band with 5-second compression time. Conduction of these tests has prepared the instrument and the operations team for science data collection during the science phase of the mission.

Buccino, Dustin↗

NASA NTRS2019

Characterization of IM7/8552 Thin-Ply and Hybrid Thin-Ply Composites

Composite materials have increasingly been used for aerospace applications due to improved performance and reduced weight compared to their metallic counterparts. Inclusion of thin-ply material, plies with cured thickness half or less than standard composites, have potential to improve performance and reduce structural weight. Limited characterization of thin-ply IM7/8552 material in 30 and 70 grams per square meter fiber areal weights has been carried out using a series of selected American Society for Testing and Materials (ASTM) tests. Tests included unnotched tension, unnotched compression, v-notched rail shear, open-hole tension, and open-hole compression. Unidirectional, cross-ply, quasiisotropic and hybrid hard laminates were included in the study, and were compared to standard-ply laminates. Properties compared include fiber volume, laminate moduli, and failure strength, with failure modes also being examined. The thin-ply specimens exhibited similar or superior performance to standard ply laminates in many of the cases compared. Improvements in strength for laminates containing thin-ply material were seen for unidirectional laminates under unnotched tension, quasi-isotropic laminates under unnotched tension and compression, and hard laminates under open hole tension. Additional investigation is required to determine appropriate ply stacking rules for hybrids of thin and standard plies to avoid undesirable failure modes such as axial splitting. However, the observed performance improvements demonstrated by the conducted ASTM tests of hybrid thin-ply hard laminates could have benefits for improved structural weight in aircraft.

Lovejoy, Andrew E.↗

NASA NTRS2004

Implementation of a Message Passing Interface into a Cloud-Resolving Model for Massively Parallel Computing

The capability for massively parallel programming (MPP) using a message passing interface (MPI) has been implemented into a three-dimensional version of the Goddard Cumulus Ensemble (GCE) model. The design for the MPP with MPI uses the concept of maintaining similar code structure between the whole domain as well as the portions after decomposition. Hence the model follows the same integration for single and multiple tasks (CPUs). Also, it provides for minimal changes to the original code, so it is easily modified and/or managed by the model developers and users who have little knowledge of MPP. The entire model domain could be sliced into one- or two-dimensional decomposition with a halo regime, which is overlaid on partial domains. The halo regime requires that no data be fetched across tasks during the computational stage, but it must be updated before the next computational stage through data exchange via MPI. For reproducible purposes, transposing data among tasks is required for spectral transform (Fast Fourier Transform, FFT), which is used in the anelastic version of the model for solving the pressure equation. The performance of the MPI-implemented codes (i.e., the compressible and anelastic versions) was tested on three different computing platforms. The major results are: 1) both versions have speedups of about 99% up to 256 tasks but not for 512 tasks; 2) the anelastic version has better speedup and efficiency because it requires more computations than that of the compressible version; 3) equal or approximately-equal numbers of slices between the x- and y- directions provide the fastest integration due to fewer data exchanges; and 4) one-dimensional slices in the x-direction result in the slowest integration due to the need for more memory relocation for computation.

Juang, Hann-Ming Henry↗