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At least 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Hybrid AI-ML and FE-based Digital Twin Predictive Modeling Framework for a PWR Coolant System Components: Updates on Multi-Time-Series-3D-Location Dependent Usages Factor Prediction

The long-term operation (LTO) of nuclear power plants (NPP) beyond their original design life of 40 years can lead to more material damage associated with cyclic fatigue under thermal-mechanical loading cycles and associated long-term exposure of reactor material to the deleterious reactor-coolant environments. However, under this LTO condition, the reactor components can still safely operate but may require more frequent Nondestructive Evaluation (NDE) of reactor components. Requiring frequent NDE inspections may lead to frequent NPP shutdowns which can lead to power outages and additional NDE inspection cost-related economic loss. The economic loss can be minimized by reducing uncertainty in life estimation of safety-critical pressure boundary components and by implementing a more digital approach such as using upcoming digital-twin (DT) technology for predicting the structural states (e.g., time and location dependent inside/outside thickness temperature, stress, strain, plastic deformation, etc.) and associated fatigue life of a component in real time. The DT framework is based on limited experimental data, Artificial-intelligence (AI)-Machine-Learning (ML) and multiphysics-computationalmechanics such as finite element- (FE) based models. Given the real-time thermal-hydraulic process measurements from several existing plant sensors, the overall goal of the DT framework is to predict the cumulative usages factors or equivalent fatigue lives in real time and at any random 3D location of the components. This includes inaccessible locations such as inside the thickness or location of a component. This prediction can be at thousands to millions of 3D point clouds or locations like conventional FE-based models, but without running an FE model in real time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Pit growth kinetics in aluminum: effects of salt loading and relative humidity

Abstract The growth kinetics of localized corrosion, e.g. pits, in corrosive environments often controls the service life of metallic components. Yet, our understanding of these kinetics is largely based on coupon-level, e.g. mass-loss, studies which provide limited insights into the evolution of individual damage events. It is critical to relate observed cumulative loss trends, such as links between changing humidity and mass loss rates, to the growth kinetics of individual pits. Towards this goal, we leverage in-situ X-ray computed tomography to measure the growth rates of over sixty pits in aluminum in four different humid, chloride environments over ≈3 days of exposure. Pit growth rates and final volumes increased with increasing droplet volume, which was observed to increase with increasing humidity and salt loading. Two factors, droplet spreading and oxide jacking, dramatically increased pit growth rates and final volumes.

Noell, Philip J. (ORCID:0000000346998999)↗
NASA NTRS2005

Simulations of Evaporating Multicomponent Fuel Drops

A paper presents additional information on the subject matter of Model of Mixing Layer With Multicomponent Evaporating Drops (NPO-30505), NASA Tech Briefs, Vol. 28, No. 3 (March 2004), page 55. To recapitulate: A mathematical model of a three-dimensional mixing layer laden with evaporating fuel drops composed of many chemical species has been derived. The model is used to perform direct numerical simulations in continuing studies directed toward understanding the behaviors of sprays of liquid petroleum fuels in furnaces, industrial combustors, and engines. The model includes governing equations formulated in an Eulerian and a Lagrangian reference frame for the gas and drops, respectively, and incorporates a concept of continuous thermodynamics, according to which the chemical composition of a fuel is described by use of a distribution function. In this investigation, the distribution function depends solely on the species molar weight. The present paper reiterates the description of the model and discusses further in-depth analysis of the previous results as well as results of additional numerical simulations assessing the effect of the mass loading. The paper reiterates the conclusions reported in the cited previous article, and states some new conclusions. Some new conclusions are: 1. The slower evaporation and the evaporation/ condensation process for multicomponent-fuel drops resulted in a reduced drop-size polydispersity compared to their single-component counterpart. 2. The inhomogeneity in the spatial distribution of the species in the layer increases with the initial mass loading. 3. As evaporation becomes faster, the assumed invariant form of the molecular- weight distribution during evaporation becomes inaccurate.

Bellan, Josette↗
NASA NTRS1977

A multilevel approach for minimum weight structural design including local and system buckling constraints

A rational multilevel approach for minimum weight structural design of truss and wing structures including local and system buckling constraints is presented. Overall proportioning of the structure is achieved at the system level subject to strength, displacement and system buckling constraints, while the detailed component designs are carried out separately at the component level satisfying local buckling constraints. Total structural weight is taken to be the objective function at the system level while employing the change in the equivalent system stiffness of the component as the component level objective function. Finite element analysis is used to predict static response while system buckling behavior is handled by incorporating a geometric stiffness matrix capability. Buckling load factors and the corresponding mode shapes are obtained by solving the eigenvalue problem associated with the assembled elastic stiffness and geometric stiffness matrices for the structural system. At the component level various local buckling failure modes are guarded against using semi-empirical formulas. Mathematical programming techniques are employed at both the system and component level.

Schmit, L. A., Jr.↗
DOE OSTI2025

Materials Engineering for High Performance and Durability Proton Exchange Membrane Water Electrolyzers

Proton exchange membrane water electrolyzers (PEMWEs) are expected to play a crucial role in the global green energy transition during the 21st century. They provide a versatile and sustainable solution for generating hydrogen with very high purity in combination with renewable energies, such as solar and wind. Despite their promise, PEMWEs face several critical problems, including high costs, performance limitations, and durability challenges, particularly at low iridium (Ir) loading on the anode. Advancing next-generation PEMWEs requires extensive work on materials engineering of all cell components, including the catalyst layer (CL), membrane, porous transport layer (PTL), bipolar plate (BPP), and gasket. This task must be performed with the complementary contribution of different modeling and characterization techniques. This review presents a critical perspective from academia, research centers, and industry, mapping main developments, remaining gaps, and strategic pathways to advance PEMWE technology. A focus is devoted to key aspects, such as operation at low Ir loading, membrane durability, multiscale transport layers, porous and non-porous flow fields, multiphysics modeling, and multipurpose characterization techniques, which are thoroughly discussed. By unifying these topics, this review provides readers with the essential knowledge to grasp current developments and tackle tomorrow's challenges in PEMWE engineering.

36 MATERIALS SCIENCE↗
NASA NTRS1984

Thermal dependence of stress-induced birefringence in single mode optical fibers

Measurements of the change in stress-induced birefringence with temperature in single mode optical fibers are reported. The fibers examined include those with low residual stress birefringence that have circular and elliptical cores. A section of each fiber was placed under constant load with weights and heated inside a furnace. Polarized light was coupled into and out of the fiber ends outside the furnace. Two mutually perpendicular polarization components were analyzed and detected at the fiber output end. Changes in the detected signal levels were monitored as a function of the temperature of the single mode fiber stressed under constant load. Discussion of results and applications to localized stress measurements at high temperatures are presented.

Berthold, J. W., III↗
DOE OSTI2022

Analysis of Cutter Blade Wear in Rotary Shear Mills

Following development of an analytical abrasive wear model to predict wear of components in a rotary shear mill, the team used a finite element analysis (FEA) approach to calculate forces and loads acting on particles responsible for abrasive wear. The analytical model related critical rotary shear process parameters (shear geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) that enabled us to model the wear of shear cutters in a rotary shear milling system developed by Forest Concepts. With proper knowledge of the forces acting between abrasive particles and cutter components built into it, the model can accurately predict wear of the cutters and provides a quality by design (QbD) approach to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches. During this reporting period, researchers at Oak Ridge National Laboratory applied an FEA package to simulate the local stresses and forces between an abrasive silica particle and two rotary shear cutters as the distance between the cutters decreases. The output of the FEA was used to provide more accurate projections of the loads applied to the particles in the analytical wear model. Comparison of the FEA force calculations are in good agreement with the loads assumed in the analytical predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Investigation of Lubricant Additive Interactions on Gasoline Particulate Filters

To understand how the composition of novel lubricant additives and their ash interact with gasoline particulate filters (GPFs), an accelerated aging protocol was conducted using three lubricant additive formulations and two GPF types. The additive packages (adpaks) consisted of Ca+Mg detergent in a 3:1 or 0:1 ratio and an anti-wear component—either zinc dialkyl dithiophosphate (ZDDP) or a novel phosphonium-phosphinate ionic liquid (IL) substitute. The particulate sampling captured amount/compositions of particulate matter (PM) generated, total particulate number, and size distribution. Five ash loadings were completed. GPF position and adpak composition affected the backpressure, ash composition, ash morphology, and captured mass. The particulate sampling indicated that the ash component consisted primarily of particles less than 50 nm in size and that the Mg-only adpak resulted in more particulate of 50–400 nm in size. Postmortem materials characterization indicated GPFs in the underfloor position had deeper penetration of ash into the walls compared to the close-coupled position. Additionally, the Mg-only adpak had a higher filter collection efficiency (>90%) and the ash particles consisted of a higher concentration of dense ash material. In contrast, four of the 3:1 Ca:Mg lubricant adpaks resulted in a collection efficiency of only 40–50%. Although the collection efficiency was higher with the Mg-only adpak, the ash layer in the GPF was not thicker, nor was the penetration into the wall more significant, and surprisingly the full useful life (FUL) backpressure was lower than with Ca:Mg adpaks. The higher density of the Mg-derived ash was the only detectable difference. A possible explanation of this observation is that Mg ash has a lower melting point and is more susceptible to densification during combustion or GPF regeneration. The substitution of IL in place of the ZDDP did not lead to any notable changes in collection efficiency or location of the ash.

42 ENGINEERING↗
NASA NTRS2001

Impact of Functionally Graded Cylinders: Theory

This final report summarizes the work funded under the Grant NAG3-2411 during the 04/05/2000-04/04/2001 period. The objective of this one-year project was to generalize the theoretical framework of the two-dimensional higher-order theory for the analysis of cylindrical functionally graded materials/structural components employed in advanced aircraft engines developed under past NASA Glenn funding. The completed generalization significantly broadens the theory's range of applicability through the incorporation of dynamic impact loading capability into its framework. Thus, it makes possible the assessment of the effect of damage due to fuel impurities, or the presence of submicron-level debris, on the life of functionally graded structural components. Applications involving advanced turbine blades and structural components for the reusable-launch vehicle (RLV) currently under development will benefit from the completed work. The theory's predictive capability is demonstrated through a numerical simulation of a one-dimensional wave propagation set up by an impulse load in a layered half-plane. Full benefit of the completed generalization of the higher-order theory described in this report will be realized upon the development of a related computer code.

Aboudi, Jacob↗
NASA NTRS1998

Open Architecture Data System for NASA Langley Combined Loads Test System

The Combined Loads Test System (COLTS) is a new structures test complex that is being developed at NASA Langley Research Center (LaRC) to test large curved panels and cylindrical shell structures. These structural components are representative of aircraft fuselage sections of subsonic and supersonic transport aircraft and cryogenic tank structures of reusable launch vehicles. Test structures are subjected to combined loading conditions that simulate realistic flight load conditions. The facility consists of two pressure-box test machines and one combined loads test machine. Each test machine possesses a unique set of requirements or research data acquisition and real-time data display. Given the complex nature of the mechanical and thermal loads to be applied to the various research test articles, each data system has been designed with connectivity attributes that support both data acquisition and data management functions. This paper addresses the research driven data acquisition requirements for each test machine and demonstrates how an open architecture data system design not only meets those needs but provides robust data sharing between data systems including the various control systems which apply spectra of mechanical and thermal loading profiles.

Lightfoot, Michael C.↗
NASA NTRS2011

Compression Behavior of Fluted-Core Composite Panels

In recent years, fiber-reinforced composites have become more accepted for aerospace applications. Specifically, during NASA s recent efforts to develop new launch vehicles, composite materials were considered and baselined for a number of structures. Because of mass and stiffness requirements, sandwich composites are often selected for many applications. However, there are a number of manufacturing and in-service concerns associated with traditional honeycomb-core sandwich composites that in certain instances may be alleviated through the use of other core materials or construction methods. Fluted-core, which consists of integral angled web members with structural radius fillers spaced between laminate face sheets, is one such construction alternative and is considered herein. Two different fluted-core designs were considered: a subscale design and a full-scale design sized for a heavy-lift-launch-vehicle interstage. In particular, axial compression of fluted-core composites was evaluated with experiments and finite-element analyses (FEA); axial compression is the primary loading condition in dry launch-vehicle barrel sections. Detailed finite-element models were developed to represent all components of the fluted-core construction, and geometrically nonlinear analyses were conducted to predict both buckling and material failures. Good agreement was obtained between test data and analyses, for both local buckling and ultimate material failure. Though the local buckling events are not catastrophic, the resulting deformations contribute to material failures. Consequently, an important observation is that the material failure loads and modes would not be captured by either linear analyses or nonlinear smeared-shell analyses. Compression-after-impact (CAI) performance of fluted core composites was also investigated by experimentally testing samples impacted with 6 ft.-lb. impact energies. It was found that such impacts reduced the ultimate load carrying capability by approximately 40% on the subscale test articles and by less than 20% on the full-scale test articles. Nondestructive inspection of the damage zones indicated that the detectable damage was limited to no more than one flute on either side of any given impact. More study is needed, but this may indicate that an inherent damage-arrest capability of fluted core could provide benefits over traditional sandwich designs in certain weight-critical applications.

Schultz, Marc R.↗
NASA NTRS1990

Mixed-Mode Bending Method for Delamination Testing

A mixed mode delamination test procedure was developed combining double cantilever beam (DCB) mode I loading and end-notch fixture (ENF) mode II loading on a split unidirectional laminate. By loading with a lever, a single applied load simultaneously produces mode I and mode II bending loads on the specimen. This mixed-mode bending (MMB) test was analyzed using both finite-element procedures and beam theory to calculate the mode I and mode II components of strain-energy release rate G(sub I) and G(sub II), respectively. A wide range of G(sub I)/G(sub II) ratios can be produced by varying the load position on the lever. As the delamination extended, the G(sub I)/G(sub II) ratios varied by less than 5%. Beam theory equations agreed closely with the finite-element results and provide a basis for selection of G(sub I)/G(sub II) test ratios and a basis for computing the mode I and mode II components of measured delamination toughness. The MMB test was demonstrated using AS4/PEEK (APC2) unidirectional laminates. The MMB test introduced in this paper is rather simple and is believed to offer several advantages over most current mixed-mode test.

Reeder, James R.↗
NASA NTRS1988

A mixed-mode bending apparatus for delamination testing

A mixed-mode delamination test procedure was developed combining double cantilever beam mode I loading and end notch flexure mode II loading on a split unidirectional laminate. By loading the specimen with a lever, a single applied load simultaneously produces mode I and II bending loads on the specimen. This mixed mode bending (MMB) test was analyzed using both finite element procedures and beam theory to calculate the mode I and II components of strain energy release rate, G sub I and G sub II, respectively. The analyses showed that a wide range of G sub I/G sub II ratios could be produced by varying the applied load position on the loading lever. As the delamination extended, the G sub I/G sub II ratios varied by less than 5 percent. The simple beam theory equations were modified to account for the elastic interaction between the two arms of the specimen and to account for shear deformations. The resulting equations agreed closely with the finite element results and provide a basis for selection of G sub I/G sub II test ratios and a basis for computing the mode I and II components of measured delamination toughness. The MMB specimen analysis and test procedures were demonstrated using unidirectional laminates.

Crews, John H., Jr.↗
NASA NTRS2017

Extraction-Separation Performance and Dynamic Modeling of Orion Test Vehicles with Adams Simulation: 3rd Edition

NASA's Orion Capsule Parachute Assembly System (CPAS) Project is now in the qualification phase of testing, and the Adams simulation has continued to evolve to model the complex dynamics experienced during the test article extraction and separation phases of flight. The ability to initiate tests near the upper altitude limit of the Orion parachute deployment envelope requires extractions from the aircraft at 35,000 ft-MSL. Engineering development phase testing of the Parachute Test Vehicle (PTV) carried by the Carriage Platform Separation System (CPSS) at altitude resulted in test support equipment hardware failures due to increased energy caused by higher true airspeeds. As a result, hardware modifications became a necessity requiring ground static testing of the textile components to be conducted and a new ground dynamic test of the extraction system to be devised. Force-displacement curves from static tests were incorporated into the Adams simulations, allowing prediction of loads, velocities and margins encountered during both flight and ground dynamic tests. The Adams simulation was then further refined by fine tuning the damping terms to match the peak loads recorded in the ground dynamic tests. The failure observed in flight testing was successfully replicated in ground testing and true safety margins of the textile components were revealed. A multi-loop energy modulator was then incorporated into the system level Adams simulation model and the effect on improving test margins be properly evaluated leading to high confidence ground verification testing of the final design solution.

Varela, Jose G.↗
NASA NTRS1988

Tubular space truss structure for SKITTER 2 robot

The Skitter 2 is a three legged transport vehicle designed to demonstrate the principle of a tripod walker in a multitude of environments. The tubular truss model of Skitter 2 is a proof of principal design. The model will replicate the operational capabilities of Skitter 2 including its ability to self-right itself. The project's focus was on the use of light weight tubular members in the final structural design. A strong design for the body was required as it will undergo the most intense loading. Triangular geometry was used extensively in the body, providing the required structural integrity and eliminating the need for cumbersome shear panels. Both the basic femur and tibia designs also relied on the strong geometry of the triangle. An intense literature search aided in the development of the most suitable weld techniques, joints, linkages, and materials required for a durable design. The hinge design features the use of spherical rod end bearings. In order to obtain a greater range of mobility in the tibia, a four-bar linkage was designed which attaches both to the femur and the tibia. All component designs, specifically the body, femur, and the tibia were optimized using the software package IDEAS 3.8A Supertab. The package provided essential deformation and stress analysis information on each component's design. The final structure incurred only a 0.0544 inch deflection in a maximum (worst case) loading situation. The highest stress experienced by any AL6061-T6 tubular member was 1920 psi. The structural integrity of the final design facilitated the use of Aluminum 6061-T6 tubing. The tubular truss structure of Skitter 2 is an effective and highly durable design. All facets of the design are structurally sound and cost effective.

Beecham, Richard↗
NASA NTRS2009

Investigation of Helicopter Longeron Cracks

Four cracked longerons, containing a total of eight cracks, were provided for study. Cracked regions were cut from the longerons. Load was applied to open the cracks, enabling crack surface examination. Examination revealed that crack propagation was driven by fatigue loading in all eight cases. Fatigue crack initiation appears to have occurred on the top edge of the longerons near geometric changes that affect component bending stiffness. Additionally, metallurgical analysis has revealed a local depletion in alloying elements in the crack initiation regions that may be a contributing factor. Fatigue crack propagation appeared to be initially driven by opening-mode loading, but at a crack length of approximately 0.5 inches (12.7 mm), there is evidence of mixed-mode crack loading. For the longest cracks studied, shear-mode displacements destroyed crack-surface features of interest over significant portions of the crack surfaces.

Newman, John A.↗
NASA NTRS2009

Investigation of Cracks Found in Helicopter Longerons

Four cracked longerons, containing a total of eight cracks, were provided for study. Cracked regions were cut from the longerons. Load was applied to open the cracks, enabling crack surface examination. Examination revealed that crack propagation was driven by fatigue loading in all eight cases. Fatigue crack initiation appears to have occurred on the top edge of the longerons near geometric changes that affect component bending stiffness. Additionally, metallurigical analysis has revealed a local depletion in alloying elements in the crack initiation regions that may be a contributing factor. Fatigue crack propagation appeared to be initially driven by opening-mode loading, but at a crack length of approximately 0.5 inches (12.7 mm), there is evidence of mixed-mode crack loading. For the longest cracks studied, shear-mode displacements destroyed crack-surface features of interest over significant portions of the crack surfaces.

Newman, John A.↗
DOE OSTI2025

Development of Surveillance Test Articles for Materials Degradation Management in MSR Environments

Materials in molten salt reactors (MSR) undergo accelerated degradation from corrosion, irradiation, and cyclic loads at elevated temperatures. Establishing a materials surveillance program to enable the assessment of material deterioration is critical to assure structural integrity of MSRs components. This presentation summarizes recent efforts towards the development of surveillance test articles for collecting various damages for monitoring materials degradation. Surveillance test articles with reduced dimensions were designed to capture creep-fatigue damage from cyclic loading at elevated temperatures. The strain evolution of test articles during thermal cycling was analyzed both numerically and experimentally. Out-of-reactor thermal cycling demonstrated successful capture of strain range for materials assessment. Moreover, test articles were subject to both mechanical loads and molten salt exposure, and the damage due to stress and corrosion was investigated. Additionally, damage inference models were developed to predict the remaining life of materials based on the accumulated damage in surveillance test articles.

36 - MATERIALS SCIENCE↗