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At least 1,387 records · Page 77

Data Mining and Visualization of High-Dimensional ICME Data for Additive Manufacturing

Integrated computational materials engineering (ICME) methods combining CALPHAD with process-based simulations can produce rich, high-dimensional data for alloy and process design. In ICME methods for metallurgical applications, the visualization and interpretation of such high-dimensional data has previously been through heat maps represented in 2 or 3 dimensions. While such an approach is ideal when one variable is varied at a time, in the case of high-dimensional data with multiple variables varied simultaneously, as is the case in additive manufacturing, interpreting the trends through two- or three-dimensional heat maps becomes challenging. Here, we propose a strategy of mixed visual data mining and quantitative analysis for high-dimensional metallurgical and process data using high-throughput thermodynamic calculations. Two case studies show the application of the proposed approach. The first case study investigated the effects of feedstock chemistry on the δ ferrite formation in 316L stainless steel powders used for binder jet additive manufacturing. The second case study linked Scheil–Gulliver calculations to a process model for dissimilar joining of aluminum alloys 5356 and 6111 during laser hot-wire additive manufacturing. Both cases contained thousands of calculated data points, showcasing the utility of visual data analysis through parallel coordinate plotting, Pearson correlation coefficient matrices, and scatter matrices compared to traditional process maps. These visualization techniques can be extended to many additive manufacturing problems to capture process–structure–property relationships for additively manufactured components.

36 MATERIALS SCIENCE↗

A mixed-mode crack analysis of isotropic solids using conservation laws of elasticity

A simple and convenient method of analysis for studying two-dimensional mixed-mode crack problems is presented. The analysis is formulated on the basis of conservation laws of elasticity and of fundamental relationships in fracture mechanics. The problem is reduced to the determination of mixed-mode stress-intensity factor solutions in terms of conservation integrals involving known auxiliary solutions. One of the salient features of the present analysis is that the stress-intensity solutions can be determined directly by using information extracted in the far field. Several examples with solutions available in the literature are solved to examine the accuracy and other characteristics of the current approach. This method is demonstrated to be superior in its numerical simplicity and computational efficiency to other approaches. Solutions of more complicated and practical engineering fracture problems dealing with the crack emanating from a circular hole are presented also to illustrate the capacity of this method

Yau, J. F.↗

Subcritical transition to turbulence in planar shear flows

The two-dimensional steady and time dependent properties of plane Poiseuille and plane Couette flows are analyzed using iterative techniques and full numerical simulation of the Navier-Stokes equations. It is shown that the finite-amplitude two-dimensional states investigated are strongly unstable to very small three-dimensional perturbations. It is also shown, through full numerical simulation, that this explosive secondary instability can explain the subcritical transitions that occur in real flows. Finally, it is shown that the three-dimensional instability can be analyzed by a linear stability analysis of a two-dimensional flow consisting of the basic parallel flow and a steady (or quasi-steady) finite-amplitude two-dimensional cellular motion.

Orszag, S. A.↗

A locally implicit finite element analysis algorithm for 3-D compressible flows

The paper outlines the research results on the development of a finite-element analysis procedure for three-dimensional compressible viscous flows. Some new algorithmic features of the computational model, such as a locally implicit solution scheme which avoids the necessity of computation and assembly of global matrices. The new algorithm makes it applicable to large-scale three-dimensional flow problems of practical interest, for example, the analysis of flows in Space Shuttle Main Engine (SSME).

Reddy, K. C.↗

Three dimensional boundary conditions in supersonic flow

A theoretical analysis of the flow pattern at a solid surface in three dimensional supersonic flow is presented. The additional information necessary to overcome the nonuniqueness associated with the body tangency condition in three dimensions was developed. The analysis is based on the fact that three dimensional waves propagate locally exactly as they do in axisymmetric flow when viewed in the osculating plane to the streamline. The supersonic flow over an infinite swept corner is examined by both the classical solution and the three dimensional solution in the osculating plane and the results are shown to be identical. A simple numerical algorithm is proposed which accounts for the three wave surfaces that interact at a solid boundary.

Rudman, S.↗

Similarity rules for effects of sidewall boundary layer in two-dimensional wind tunnels

A simple analysis of the interaction of the model pressure field with the boundary layer on an unventilated wind tunnel wall is presented. It is shown that the effects of this interaction are similar to compressibility effects for sidewall boundary layers in two dimensional wind tunnels. This similarity is used to derive modified forms of the Prandtl Glauert rule for subsonic flow and the von Karman rule for transonic flow which are validated by comparison with experimental data. The three dimensional interaction problem is discussed, and it is shown that model pressure field/wall boundary layer interaction effects are not similar to compressibility effects in three dimensional wind tunnels.

Barnwell, R. W.↗

Nonlinear temperature dependent failure analysis of finite width composite laminates

A quasi-three dimensional, nonlinear elastic finite element stress analysis of finite width composite laminates including curing stresses is presented. Cross-ply, angle-ply, and two quasi-isotropic graphite/epoxy laminates are studied. Curing stresses are calculated using temperature dependent elastic properties that are input as percent retention curves, and stresses due to mechanical loading in the form of an axial strain are calculated using tangent modulii obtained by Ramberg-Osgood parameters. It is shown that curing stresses and stresses due to tensile loading are significant as edge effects in all types of laminate studies. The tensor polynomial failure criterion is used to predict the initiation of failure. The mode of failure is predicted by examining individual stress contributions to the tensor polynomial.

Nagarkar, A. P.↗

An elastic-plastic finite-element analysis of the J-resistance curve using a CTOD criterion

The fracture process in compact and bend specimens was simulated using a two-dimensional finite-element analysis of the J-resistance (J-R) curve and a CTOD criterion. The J-R curves were calculated from the numerical results for each specimen type using several different methods. In general, the J-R curves obtained for the bend specimens were found to be higher than those for the compact specimens, especially beyond maximum load. However, below the maximum load, the modified deformation theory of plasticity and the contour-integral J(r) method resulted in very similar J-R curves for both specimen types.

Newman, J. C., Jr.↗

Minimum mass design of large-scale space trusses subjected to thermal gradients

Lightweight, deployable trusses are commonly used to support space-borne instruments including RF reflectors, radar panels, and telescope optics. While in orbit, these support structures are subjected to thermal gradients that vary with altitude, location in orbit, and self-shadowing. Since these instruments have tight dimensional-stability requirements, their truss members are often covered with multi-layer insulation (MLI) blankets to minimize thermal distortions. This paper develops a radiation heat transfer model to predict the thermal gradient experienced by a triangular truss supporting a long, linear radar panel in Medium Earth Orbit (MEO). The influence of self-shadowing effects of the radar panel are included in the analysis, and the influence of both MLI thickness and outer covers/coatings on the magnitude of the thermal gradient are formed into a simple, two-dimensional analysis. This thermal model is then used to size and estimate the structural mass of a triangular truss that meets a given set of structural requirements.

thermal truss analysis↗

High Fidelity Failure Analysis for a Composite Fuselage Section

A high fidelity delamination failure analysis was developed by combining a local failure analysis with a global full-scale finite element structural analysis to address strength and delamination failure in a single package. The methodology was demonstrated through a local three-dimensional pull-off failure analysis and a geometrically nonlinear structural analysis of a five-foot composite helicopter fuselage section. Pull-off specimens were used to identify potential debonding failure of co-cured skin-stringer/frame fuselage structures. An investigation of the failed pull-off specimens was performed to determine the location of the failure initiation. Three-dimensional strain energy release rate analysis indicates that the delamination initiation and growth is controlled by Mode 1 opening mode. The bending moment at the delamination tip was identified as the crucial factor controlling the failure. The geometrically nonlinear structural analysis of a five-foot composite fuselage section was performed using a detailed finite element model. Loads were applied along the periphery of the subcomponent using displacement fields generated from solutions of a full-vehicle model.

Li, Jain↗

Computation of aircraft component flow fields at transonic Mach numbers using a three-dimensional Navier-Stokes algorithm

A computer analysis was developed for calculating steady (or unsteady) three-dimensional aircraft component flow fields. This algorithm, called ENS3D, can compute the flow field for the following configurations: diffuser duct/thrust nozzle, isolated wing, isolated fuselage, wing/fuselage with or without integrated inlet and exhaust, nacelle/inlet, nacelle (fuselage) afterbody/exhaust jet, complete transport engine installation, and multicomponent configurations using zonal grid generation technique. Solutions can be obtained for subsonic, transonic, or hypersonic freestream speeds. The algorithm can solve either the Euler equations for inviscid flow, the thin shear layer Navier-Stokes equations for viscous flow, or the full Navier-Stokes equations for viscous flow. The flow field solution is determined on a body-fitted computational grid. A fully-implicit alternating direction implicit method is employed for the solution of the finite difference equations. For viscous computations, either a two layer eddy-viscosity turbulence model or the k-epsilon two equation transport model can be used to achieve mathematical closure.

Shrewsbury, George D.↗

An Aerodynamic Analysis of a Mixed Flow Turbine

The aerodynamic performance of a high-work Mixed Flow Turbine (MFT) is computed and compared with experimental data. A three dimensional (3-D) viscous analysis is applied to the single stage MFT geometry with a relatively long upstream transition duct. Predicted vane surface static pressures and circumferentially averaged spanwise quantities at stator and rotor exits agree favorably with data. Compared to the results of axisymmetric flow analysis from design intent, the 3-D computation agrees much better especially in the endwall regions where throughflow prediction fails to assess the loss mechanism properly. Potential sources of performance loss such as tip leakage and secondary flows are also properly captured by the analysis.

Kim, Chan M.↗

Sublaminate analysis of interlaminar fracture in composites. II - Applications

A validation of the sublaminate analysis method of Armanios and Rehfield (1989) is provided by comparison of the predictions with a quasi-three-dimensional finite-element analysis. A comparison of the total strain-energy release rate with a classical plate model is also provided. Closed-form expressions for the total strain-energy rate and the strain-energy release-rate components are developed. The sublaminate analysis developed is simple, and the results are generated using a desktop computer.

Armanios, Erian A.↗

A finite-element analysis of fatigue crack closure

The paper is concerned with the application of a two-dimensional, nonlinear, finite-element analysis using an incremental theory of plasticity to predict crack-closure and crack-opening stresses during the crack-growth process under cyclic loading. A two-dimensional finite-element computer program is developed, which accounts for both elastic-plastic material behavior and changing boundary conditions associated with crack extension and intermittent contact of the crack surfaces under cyclic loading. An efficient technique to account for changing boundary conditions under cyclic loading is also incorporated into the nonlinear analysis program. This program is used to study crack extension and crack closure behavior in a center-cracked panel under constant-amplitude and two-level block loading. The calculated crack-opening stresses are found to be quantitatively consistent with experimental measurements.

Newman, J. C., Jr.↗

Transonic CFD applications at Boeing

The use of computational methods for three dimensional transonic flow design and analysis at the Boeing Company is presented. A range of computational tools consisting of production tools for every day use by project engineers, expert user tools for special applications by computational researchers, and an emerging tool which may see considerable use in the near future are described. These methods include full potential and Euler solvers, some coupled to three dimensional boundary layer analysis methods, for transonic flow analysis about nacelle, wing-body, wing-body-strut-nacelle, and complete aircraft configurations. As the examples presented show, such a toolbox of codes is necessary for the variety of applications typical of an industrial environment. Such a toolbox of codes makes possible aerodynamic advances not previously achievable in a timely manner, if at all.

Tinoco, E. N.↗

Systematic characterization of unknown compounds via dimensionality reduction of time series

Analysis of ambient aerosols provides valuable insight into particle sources and formation chemistry. However, due to the complexity of atmospheric data and the dynamic nature of aerosol composition, a substantial fraction of data often become discarded by conventional analysis methods. Furthermore, a large fraction of chemical species within those data are unidentifiable due to a lack of matching spectral information, resulting in suboptimal characterization of chemical composition. Previous work has demonstrated techniques for cataloging analytes in a chromatographic dataset by deconvolution of mass spectra, but integration of these analytes throughout a large dataset remains time consuming. Here, we present a method to automatically identify an ion for quantitation for single-ion chromatogram based peak fitting and integration, enabling comprehensive integration of analytes with minimal user interaction. The resulting time series are clustered with a machine-learning based dimensionality reduction technique to systematically investigate the underlying characteristics of the categorized analytes and gain new insights into the chemical composition and physicochemical properties of the unidentifiable analytes. We apply these methods to existing atmospheric datasets collected in Manacapuru, Brazil during the GoAmazon2014/5 campaign to identify new analytes and interpret their variability and transformations in the atmosphere. The analysis results generate 408 time series from cataloged analytes of interest, and the clustering of those time series with spherical k-means results in 8 distinct clusters. We find the analytes form clusters based on their distinct physicochemical properties, demonstrating the method’s ability to systematically identify and selectively filter contaminants and instrumental analytes and characterize the unidentifiable analytes.

54 ENVIRONMENTAL SCIENCES↗

A rocket engine design expert system

The overall structure and capabilities of an expert system designed to evaluate rocket engine performance are described. The expert system incorporates a JANNAF standard reference computer code to determine rocket engine performance and a state-of-the-art finite element computer code to calculate the interactions between propellant injection, energy release in the combustion chamber, and regenerative cooling heat transfer. Rule-of-thumb heuristics were incorporated for the hydrogen-oxygen coaxial injector design, including a minimum gap size constraint on the total number of injector elements. One-dimensional equilibrium chemistry was employed in the energy release analysis of the combustion chamber and three-dimensional finite-difference analysis of the regenerative cooling channels was used to calculate the pressure drop along the channels and the coolant temperature as it exits the coolant circuit. Inputting values to describe the geometry and state properties of the entire system is done directly from the computer keyboard. Graphical display of all output results from the computer code analyses is facilitated by menu selection of up to five dependent variables per plot.

Davidian, Kenneth J.↗