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At least 1,405 records · Page 78
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

An Integrated Numerical Method to Predict the Strain Sensing Behavior of Flexible Conductive Fibers under Electric–Thermal Conditions

Flexible conductive textiles have attracted an increasing amount of attention due to being flexible and stretchable with multi-functions, in addition to the strain sensing function. In this paper, an integrated numerical method is established to predict the strain sensing behavior of PPy-coated flexible conductive fibers. Based on our previous investigation on the strain sensing behavior of the PPy-coated elastic conductive fibers, it has been known that the main strain sensing mechanisms of the conductive fibers are micro-cracks opening under stretching and closing under unloading. Therefore, in the numerical approach, extended finite element method is used to simulate the multi-crack initiation and propagation. Then, by establishing a representative element model including a single crack, the resistance variation with the increase in crack width/depth can be obtained using the electric–thermal package in ABAQUS software. Combining the relationship between crack width and strain, the relationship between fractional increment in resistance (ΔR/R{sub 0}) and the strain can be obtained. The prediction of the fractional increment in resistance (ΔR/R{sub 0}) versus strain is consistent with the experimental results of PPy-coated Lycra fibers. The new integrated method is further verified by experimental results of PPy-coated XLA fibers, showing that the integrated numerical approach can capture the complicated strain sensing mechanisms of PPy-coated elastic fibers and predict the strain sensing behavior of flexible conductive fibers. This approach will make it possible to shorten the period, and reduce the cost in R&D of the PPy-coated electrically conductive fibers, comparing with the corresponding experimental work.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Computational simulation of intermingled-fiber hybrid composite behavior

Three-dimensional finite-element analysis and a micromechanics based computer code ICAN (Integrated Composite Analyzer) are used to predict the composite properties and microstresses of a unidirectional graphite/epoxy primary composite with varying percentages of S-glass fibers used as hydridizing fibers at a total fiber volume of 0.54. The three-dimensional finite-element model used in the analyses consists of a group of nine fibers, all unidirectional, in a three-by-three unit cell array. There is generally good agreement between the composite properties and microstresses obtained from both methods. The results indicate that the finite-element methods and the micromechanics equations embedded in the ICAN computer code can be used to obtain the properties of intermingled fiber hybrid composites needed for the analysis/design of hybrid composite structures. However, the finite-element model should be big enough to be able to simulate the conditions assumed in the micromechanics equations.

Mital, Subodh K.↗
DOE OSTI2024

NEAMS-Multiphysics MOOSE End Year Framework Activities FY20

The Multiphysics Object Oriented Simulation Environment (MOOSE) is a general finite element package meant for high performance solution of multiphysics problems in science and engineering. In this report, we present additions and enhancements to MOOSE funded by the Nuclear Engineering Advanced Modeling and Simulation (NEAMS) program. NEAMS-funded MOOSE framework library improvements include: expansion of support for multi-level multi-application restart; enhancement of coupling between native MOOSE applications and external libraries; addition of a sparse automatic differentiation (AD) container enabling non-local degree of freedom coupling; block-specific quadrature rules; further development of an eigenvalue executioner; faster setup of periodic boundary conditions; and creation of a mesh meta-data system streamlining simulation startup. Besides developing the framework library, NEAMS funds were used to overhaul a swath of important MOOSE infrastructure in order to substantially improve user experience. These critical infrastructure changes included adapting MOOSE to python 3, improving the test harness to catch race conditions, and most importantly transitioning MOOSE to use Conda, a globally known packaging system, that greatly eases software adoption.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2016

Stochastic-Strength-Based Damage Simulation of Ceramic Matrix Composite Laminates

The Finite Element Analysis-Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to characterize and predict the progressive damage response of silicon-carbide-fiber-reinforced reaction-bonded silicon nitride matrix (SiC/RBSN) composite laminate tensile specimens. Studied were unidirectional laminates [0] (sub 8), [10] (sub 8), [45] (sub 8), and [90] (sub 8); cross-ply laminates [0 (sub 2) divided by 90 (sub 2),]s; angled-ply laminates [plus 45 (sub 2) divided by -45 (sub 2), ]s; doubled-edge-notched [0] (sub 8), laminates; and central-hole laminates. Results correlated well with the experimental data. This work was performed as a validation and benchmarking exercise of the FEAMAC/CARES program. FEAMAC/CARES simulates stochastic-based discrete-event progressive damage of ceramic matrix composite and polymer matrix composite material structures. It couples three software programs: (1) the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC), (2) the Ceramics Analysis and Reliability Evaluation of Structures Life Prediction Program (CARES/Life), and (3) the Abaqus finite element analysis program. MAC/GMC contributes multiscale modeling capabilities and micromechanics relations to determine stresses and deformations at the microscale of the composite material repeating-unit-cell (RUC). CARES/Life contributes statistical multiaxial failure criteria that can be applied to the individual brittle-material constituents of the RUC, and Abaqus is used to model the overall composite structure. For each FEAMAC/CARES simulation trial, the stochastic nature of brittle material strength results in random, discrete damage events that incrementally progress until ultimate structural failure.

composite structures↗
NASA NTRS2004

Higher-Order Finite Elements for Computing Thermal Radiation

Two variants of the finite-element method have been developed for use in computational simulations of radiative transfers of heat among diffuse gray surfaces. Both variants involve the use of higher-order finite elements, across which temperatures and radiative quantities are assumed to vary according to certain approximations. In this and other applications, higher-order finite elements are used to increase (relative to classical finite elements, which are assumed to be isothermal) the accuracies of final numerical results without having to refine computational meshes excessively and thereby incur excessive computation times. One of the variants is termed the radiation sub-element (RSE) method, which, itself, is subject to a number of variations. This is the simplest and most straightforward approach to representation of spatially variable surface radiation. Any computer code that, heretofore, could model surface-to-surface radiation can incorporate the RSE method without major modifications. In the basic form of the RSE method, each finite element selected for use in computing radiative heat transfer is considered to be a parent element and is divided into sub-elements for the purpose of solving the surface-to-surface radiation-exchange problem. The sub-elements are then treated as classical finite elements; that is, they are assumed to be isothermal, and their view factors and absorbed heat fluxes are calculated accordingly. The heat fluxes absorbed by the sub-elements are then transferred back to the parent element to obtain a radiative heat flux that varies spatially across the parent element. Variants of the RSE method involve the use of polynomials to interpolate and/or extrapolate to approximate spatial variations of physical quantities. The other variant of the finite-element method is termed the integration method (IM). Unlike in the RSE methods, the parent finite elements are not subdivided into smaller elements, and neither isothermality nor other unrealistic physical conditions are assumed. Instead, the equations of radiative heat transfer are integrated numerically over the parent finite elements by use of a computationally efficient Gaussian integration scheme.

Gould, Dana C.↗
DOE OSTI2018

Control rod treatment for FEM based radiation transport methods

This paper presents a novel control rod treatment for finite element method (FEM) based reactor physics simulations. The new method falls into the class of homogenization methods which treat material interfaces within mesh elements by defining a representative, homogenized nuclear cross section set. In contrast to existing homogenization based cusping treatments that attempt to approximate flux-volume weighting of the cross sections, we propose to exactly integrate terms appearing in the variational form of the transport or diffusion equation over mixed material elements. This goal is achieved by defining smoothly varying cross sections in elements that straddle material boundaries. It is shown that the smoothly varying cross sections can be obtained by projecting the piecewise set of cross sections onto the set of Legendre polynomials up to a finite order. Implementation of smoothly varying cross sections is supported within the Rattlesnake radiation multiphysics code that is currently under development at the Idaho National Laboratory. Homogenization methods traditionally suffer from cusping effects that originate from overestimation of absorption cross sections in strongly neutron-absorbing materials as found in control rods. We demonstrate that the presented method is (1) highly effective in removing cusping effects and (2) provides accurate results based on the C5G7-TD benchmark, a time-dependent version of the C5G7 benchmark.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1990

The semidiscrete Galerkin finite element modeling of compressible viscous flow past an airfoil

The primary project was the numerical simulation, by a finite element/finite difference method, of the viscous flow about an airfoil. The secondary project involved the numerical simulation of the three-dimensional separated and vortex-dominated flow about a hemispherically capped cylinder in the transonic regime. Preliminary calculations were started for the hemisphere-cylinder at 0 and 5 degree angle of attack. The solution of the flow field about airfoils and wings is required to determine the important parameters of lift, moment, and drag. Viscous effects must be accounted for if the drag is to be accurately calculated. At present there are basically two approaches to the numerical simulation of the flow field, the use of fully viscous models and the inviscid/viscous models. The fully viscous models require the solution of an approximation of the Navier-Stokes equations and therefore should simulate most of the physical mechanisms. A fast, accurate, and computationally efficient inviscid flow solver was recently developed by Hartwich. It is thought that Hartwich's program coupled to a fast, accurate, and computationally efficient boundary layer code, will make an excellent tool for airfoil design. The purpose of the primary project was to develop a compressible boundary layer code using the semidiscrete Galerkin finite element method. The numerical scheme employed used the combination of a Dorodnitsyn formulation of the boundary layer equations, with a finite difference/finite element procedure (semidiscrete Galerkin method), in the solution of the compressible two-dimensional boundary layer equations. A laminar compressible boundary layer code was developed and tested for a NACA 0012 airfoil at a Mach number of 0.5, a Reynolds number of 5000, and zero angle of attack. At present the boundary layer program solves up to, but not beyond, separation.

Meade, Andrew J.↗
DOE OSTI2018

A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling

This work proposes a finite element (FE) analysis workflow to simulate directed energy deposition (DED) additive manufacturing at a macroscopic length scale (i.e. part length scale) and to predict thermal conditions during manufacturing, as well as distortions, strength and residual stresses at the completion of manufacturing. The proposed analysis method incorporates a multi-step FE workflow to elucidate the thermal and mechanical responses in laser engineered net shaping (LENS) manufacturing. For each time step, a thermal element activation scheme captures the material deposition process. Then, activated elements and their associated geometry are analyzed first thermally for heat flow due to radiation, convection, and conduction, and then mechanically for the resulting stresses, displacements, and material property evolution. Finally, simulations agree with experimentally measured in situ thermal measurements for simple cylindrical build geometries, as well as general trends of local hardness distribution and plastic strain accumulation (represented by relative distribution of geometrically necessary dislocations).

42 ENGINEERING↗
DOE OSTI2020

Effect of heat treatment on microstructural evolution and hardness homogeneity in laser powder bed fusion of alloy 718

The thermal history developed in laser powder bed fusion (LPBF) processes has been shown to be complex resulting in equally complex microstructures and mechanical properties. Microscopic observations and Vickers micro-hardness mapping measurements were carried out on diff ;erent section planes of LPBF alloy 718 cuboids. Three-dimensional finite element analysis was used to simulate thermal history and to predict the residual stress distribution in the as-built material. Computational thermodynamics was used to predict the micro-segregation and nucleation driving force of various phases in the bulk and in segregated regions. Varied heat-treatments such as simulated hot isostatic pressing, and double aging were applied. Their influence on the microstructure, microsegregation, precipitate formation, and micro-hardness variations of LPBF alloy 718 were investigated. Hardness map results showed heterogeneous micro-hardness on the xy- and xz-planes of the as-built parts where the bottom plane and center regions had larger hardness of ~315 HV 0.5 while the top plane and contours showed hardness of ~300 HV 0.5 . It was found that the aging treatment increased the overall hardness of the as-built condition from ~310 HV 0.5 to 470 HV 0.5 but also increased the hardness gradient throughout the coupon. After simulated hot isostatic pressing process (i.e., without applied pressure) at 1020 °C for 4 h followed by water quench (HIPWQ), the hardness gradient and hardness was minimized (~210 HV 0.5 ) as the microstructure transitioned from heterogeneous columnar grains in the as-built condition to more uniform recrystallized grains. A double aging treatment was applied to enhance hardness from ~210 HV 0.5 to ~440 HV 0.5 . Finally, HIPWQ followed by double aging produced a homogeneous microstructure and more uniform hardness map with enhanced mechanical properties in LPBF alloy 718 coupons.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A velocity/stress mixed stabilized nodal finite element for elastodynamics: Analysis and computations with strongly and weakly enforced boundary conditions

A new nodal mixed finite element is proposed for the simulation of linear elastodynamics and wave propagation problems in time domain. Our method is based on equal-order interpolation discrete spaces for both the velocity (or displacement) and stress (or strain) tensor variables. The mixed form is derived using either the velocity/stress or velocity/strain pair of unknowns, the latter being instrumental in extensions of the method to nonlinear mechanics. The proposed approach works equally well on hexahedral or tetrahedral grids and, for this reason, it is suitable for time-domain engineering applications in complex geometry. The peculiarity of the proposed approach is the use of the rate form of the stress update equation, which yields a set of governing equations with the structure of a non-dissipative space/time Friedrichs’ system. We complement standard traction boundary conditions for the stress with strongly and weakly enforced boundary conditions for the velocity (or displacement). Weakly enforced boundary conditions are particularly suitable when considering complex geometrical shapes, because they do not require dedicated data structures for the imposition of the boundary degrees of freedom, but, rather, they utilize the structure of the variational formulation. Here we also show how the framework of weakly enforced boundary conditions can be used to develop variational forms for multi-domain simulations of heterogeneous media. A complete analysis including stability and convergence proofs is included, in the case of a space–time variational approach. A series of computational tests are used to demonstrate and verify the performance of the proposed approach.

42 ENGINEERING↗
DOE OSTI2026

On the roles of welding residual stresses in determination of fracture toughness in austenitic stainless steel SUS 304 pipeline girth welds

Welding residual stresses especially the high tensile stresses are proved to have negative impacts on the fatigue and fracture behaviors of welded structures. In this study, a virtual fabrication of test specimens from welding process to specimen preparation was carried out by numerical simulation. An austenitic stainless steel multi-pass pipe welding was simulated by transient thermal–mechanical finite element analysis, the residual stresses were then mapped into the test specimen to evaluate fracture toughness. The findings in this study confirmed that, residual stress can be high in a sub-sized compact tensile specimen, which may accelerate or hinder the crack propagation during actual fatigue and fracture tests as reported in recent years. The influence of the cutting location and orientation of the specimen on fracture performance was investigated systematically to provide a fundamental understanding of welding residual stress and necessary insights into the specimen preparation procedure. Considering the limitation of measuring techniques and the complexity of the stress distribution, the developed numerical model can be a very useful tool to elucidate the stress evolution and quantify the effect of remaining welding stress on fracture toughness.

Fracture behavior↗
DOE OSTI2016

Mitigating cutting-induced plasticity in the contour method, Part 2: Numerical analysis

Cutting-induced plasticity can have a significant effect on the measurement accuracy of the contour method. The present study examines the benefit of a double-embedded cutting configuration that relies on self-restraint of the specimen, relative to conventional edge-crack cutting configurations. A series of finite element analyses are used to simulate the planar sectioning performed during double-embedded and conventional edge-crack contour cutting configurations. The results of numerical analyses are first compared to measured results to validate the cutting simulations. The simulations are then used to compare the efficacy of different cutting configurations by predicting the deviation of the residual stress profile from an original (pre-cutting) reference stress field, and the extent of cutting-induced plasticity. Comparisons reveal that while the double-embedded cutting configuration produces the most accurate residual stress measurements, the highest levels of plastic flow are generated in this process. As a result, this cutting-induced plastic deformation is, however, largely confined to small ligaments formed as a consequence of the sample sectioning process, and as such it does not significantly affect the back-calculated residual stress field.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Parametric study of residual stress formation in Wire and Arc Additive Manufacturing

Here, a finite element model was created to simulate the Wire Arc Additive Manufacturing (WAAM) thermal and mechanical processes of Inconel 718 on a A36 steel substrate, as well as the effects of process parameters on Residual Stress (RS). The model was verified using temperature data obtained from three thermocouples attached to the upper surface of the build substrate and micro-strain measurements obtained from Neutron Diffraction (ND) measurement. The model was then used to study the effects of changing the torch travel speed and interlayer dwell time. The study found that travel speed has little effect on RS when maintaining the same heat input rate. As well, the interlayer dwell time has a strong effect on RS. Reducing the dwell time causes the stress profiles to become relatively uniform and a high-stress region extends deeper along the build direction. This study provides important insight into mechanical stresses inside large walls made by the WAAM method.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Insight into the deformation features and capacity loss mechanisms of lithium-ion pouch cells under spherical indentation conditions

Mechanical deformation under extreme conditions is one of the important reasons for the failure of lithium-ion batteries in automotive application. However, the deformation features and component failure of lithium-ion cells to external loading has never been a design consideration. Here, in this study, we conduct spherical indentation tests on a dozen of lithium-ion cells with different capacities under different control mode conditions to investigate their deformation features and capacity loss mechanisms. The experimental results show that, under mechanical deformation conditions, internal faults of cells occur in stages, and energy accumulation and sudden release are two key processes of cell's mechanical failure. The cells' state of charge is the main factor affecting their thermal runaway behaviors. In addition, a finite element model is developed to simulate the deformation features and the failure mechanism of key components of lithium-ion pouch cells; the 3D x-ray computed tomography is employed to demonstrate its internal configuration. With this model, the force-strain response, the deformation features as well as the size of the failure area of lithium-ion cells under spherical indentation conditions are accurately predicted. In 3D x-ray computed tomography images, unique mud cracks in cooper current collector are observed, and the influence mechanisms of the isolated fragments on the cell capacities are revealed. These results may provide useful information for the mechanical structure design of the components of lithium-ion pouch cells.

25 ENERGY STORAGE↗
DOE OSTI2023

Modeling the interfacial failure and resulting mechanical properties of z-pinned additively manufactured composites

The mechanical properties of Fused Filament Fabrication (FFF) parts are limited in the build direction, albeit advantages such as design flexibility and in-house customization. Here, in this paper, a novel z-pinning approach that enhances mechanical properties in the build direction by depositing material across multiple layers within the part was investigated through numerical simulations and validated experimentally. A finite element model for z-pinned composite structures was developed by assigning fiber-orientation dependent material properties obtained using a micromechanics approach to beads and pins. The bead-to-bead and pin-to-pin adhesions within the z-pinned structures were modeled using a cohesive traction separation law. The properties of cohesive elements for carbon fiber-reinforced polylactic acid (CF-PLA) z-pinned composites were calibrated using tensile experiments. The elastic modulus and tensile strength of CF-PLA z-pinned composites in the build direction were predicted with the developed numerical model. The numerical investigation on various geometrical parameters revealed that the largest pin volume increases the stiffness and tensile strength by 40% and thus, has the greatest influence on the mechanical properties of the z-pinned composites. The effect of z-pin geometrical parameters on the mechanical properties was summarized to aid in the design of z-pinned additively manufactured composite structures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Seismic response of vertical dry storage casks under three-dimensional earthquake motions

Ensuring the long-term seismic safety of dry storage casks (DSCs) is becoming increasingly critical as these systems evolve from temporary to de facto permanent repositories for spent nuclear fuels. Traditional seismic soil–structure interaction (SSI) assessment methods use one-dimensional deconvolution or simplified boundary conditions to model incident waves. Although computationally appealing, simplifying assumptions may alter the seismic risk by neglecting the full complexity of three-dimensional (3D) wave propagation effects. To address this challenge, this paper introduces a novel high-fidelity computational framework that leverages the Domain Reduction Method (DRM) with perfectly matched layers (PML) to accurately transfer complex, 3D seismic wavefields from regional-scale fault-rupture simulations into local-scale finite element models of DSCs. Using broadband, physics-based ground motions from a generic M w 7.0 strike-slip event, both single-cask and multi-cask configurations were investigated under near- and far-field conditions. Emphasis is placed on capturing complex SSI, spatial variability in the ground motion, and nonlinear phenomena such as cask rocking and sliding. Numerical results demonstrate that near-field conditions, where forward directivity and fling-step effects dominate, lead to significantly higher DSC rocking and sliding. Far-field cases, by contrast, generally exhibit modest responses. Incorporating SSI tends to amplify or alter DSC response spectra and introduce response variability, which underscores the need for site-specific evaluations and robust modeling approaches to ensure the seismic integrity of DSCs in interim spent fuel storage installations.

Das, Tonmoy↗
DOE OSTI2022

Thermoplasticity of metallic glasses: Processing and applications

Owing to their extremely low shear viscosity and fragility, bulk metallic glasses (BMGs) are envisioned as new net-shaping material replacing conventionally used crystalline metals for various applications. The first part of this review describes the general technique and kinetics of thermoplastic forming. The second part elaborates on the thermal processing capability of metallic glasses from atomic- to meter-scale. The micro-/nano-structure obtained after various quenching rates followed by temperature, time and heating rate dependent thermoplastic forming is described in the third section. The deformation behavior and flow kinetics of BMGs in terms of composition, mold features, and applied conditions are elaborated in the fourth section. The variation of volume and enthalpy at the supercooled liquid region, strength retention of metallic glasses compared to other conventional metals and alloys, and kinetics of liquid fragility are given in the fifth section. Finite element modeling and molecular dynamics simulations of high-temperature deformation in BMGs are presented in the sixth part. Finally, thermally-formed BMGs used for different applications, including energy, biomedical and micro-optics, are presented in the final part. Altogether, this review provides an overview of shaping capabilities and modifications in the macro-scale properties and short-to-medium range order of BMGs upon thermoplastic forming.

36 MATERIALS SCIENCE↗