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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Assessment of Buffer-IPyC Thermomechanical Debonding Behavior Using New Experiment Strength Data in BISON

TRIstructural ISOtropic (TRISO) single sub-millimeter-diameter nuclear fuel particle consists of a spherical fuel kernel surrounded by four coating layers. During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. To predict TRISO thermomechanical performance, multi-physics models have been built that are continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for TRISO particle simulations. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Assessment of buffer-IPyC thermomechanical debonding behavior using new experimental strength data in BISON

TRIstructural ISOtropic (TRISO) fuel is a nuclear fuel commonly used in High Temperature Gas-cooled Reactors (HTGRs). A single sub-millimeter-diameter TRISO fuel particle consists of a spherical fuel kernel surrounded by four coating layers: a low-density pyrocarbon buffer layer, an inner pyrolytic carbon (IPyC) layer, a silicon carbide (SiC) layer, and an outer pyrolytic carbon (OPyC) layer. The kernel is commonly made of UO2 or a mixture of uranium carbide and uranium oxide (UCO). During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. Not all irradiated particles will experience buffer-IPyC gap formation. The debonding may be partial, or it may be nearly total. However, from post-irradiation examination of UCO TRISO fuels irradiated as part of the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program, it was concluded that partial buffer-IPyC debonding was the most common type of buffer-IPyC interaction. To predict TRISO thermomechanical performance, multi-physics models have been built that are being continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for 1D, 2D, and 3D TRISO particle simulations. This code is used to calculate fuel temperature, kernel swelling, buffer densification, thermal and irradiation creep, fracture, and fission gas production and release. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated AGR TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. That observation is also implemented in the TRISO interface debonding model. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2014

Calibration and Validation of a Finite ELement Model of THor-K Anthropomorphic Test Device for Aerospace Safety Applications

The THOR anthropomorphic test device (ATD) has been developed and continuously improved by the National Highway Traffic Safety Administration to provide automotive manufacturers an advanced tool that can be used to assess the injury risk of vehicle occupants in crash tests. Recently, a series of modifications were completed to improve the biofidelity of THOR ATD [1]. The updated THOR Modification Kit (THOR-K) ATD was employed at Wright-Patterson Air Base in 22 impact tests in three configurations: vertical, lateral, and spinal [2]. Although a computational finite element (FE) model of the THOR had been previously developed [3], updates to the model were needed to incorporate the recent changes in the modification kit. The main goal of this study was to develop and validate a FE model of the THOR-K ATD. The CAD drawings of the THOR-K ATD were reviewed and FE models were developed for the updated parts. For example, the head-skin geometry was found to change significantly, so its model was re-meshed (Fig. 1a). A protocol was developed to calibrate each component identified as key to the kinematic and kinetic response of the THOR-K head/neck ATD FE model (Fig. 1b). The available ATD tests were divided in two groups: a) calibration tests where the unknown material parameters of deformable parts (e.g., head skin, pelvis foam) were optimized to match the data and b) validation tests where the model response was only compared with test data by calculating their score using CORrelation and Analysis (CORA) rating system. Finally, the whole ATD model was validated under horizontal-, vertical-, and lateral-loading conditions against data recorded in the Wright Patterson tests [2]. Overall, the final THOR-K ATD model developed in this study is shown to respond similarly to the ATD in all validation tests. This good performance indicates that the optimization performed during calibration by using the CORA score as objective function is not test specific. Therefore confidence is provided in the ATD model for uses in predicting response in test conditions not performed in this study such those observed in the spacecraft landing. Comparison studies with ATD and human models may also be performed to contribute to future changes in THOR ATD design in an effort to improve its biofidelity, which has been traditionally based on post-mortem human subject testing and designer experience.

Putnam, J. B.↗
DOE OSTI2021

Continuous Integration, In-Code Documentation, and Automation for Nuclear Quality Assurance Conformance

The Multiphysics Object Oriented Simulation Environment (MOOSE) is an open-source, finite element framework for solving highly coupled sets of nonlinear equations. The development of the framework and applications occurs concurrently using an agile, continuous-integration software package. Included in the framework is an in-code, extensible documentation system. Using these two tools in union with the repository management tools GitHub and GitLab, a software quality plan was created and followed such that MOOSE and a MOOSE-based application (BISON) have been shown to meet the American Society of Mechanical Engineers’ Nuclear Quality Assurance-1 standard. The approach relies heavily on automation for both testing and documentation. The resulting effort demonstrates that a rigorous software quality plan may be implemented that incurs a minimal impact on day-to-day development of the software, satisfying the stringent guidelines necessary to operate the software in a safety function within a nuclear facility.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1988

A virtual crack-closure technique for calculating stress intensity factors for cracked three dimensional bodies

A three-dimensional virtual crack-closure technique is presented which calculates the strain energy release rates and the stress intensity factors using only nodal forces and displacements from a standard finite element analysis. The technique is an extension of the Rybicki-Kanninen (1977) method, and it assumes that any continuous function can be approximated by a finite number of straight line segments. Results obtained by the method for surface cracked plates with and without notches agree favorably with previous results.

Shivakumar, K. N.↗
DOE OSTI2021

Analysis of the SBP-SAT Stabilization for Finite Element Methods Part II: Entropy Stability

In the hyperbolic research community, there exists the strong belief that a continuous Galerkin scheme is notoriously unstable and additional stabilization terms have to be added to guarantee stability. In the first part of the series, the application of simultaneous approximation terms for linear problems is investigated where the boundary conditions are imposed weakly. By applying this technique, the authors demonstrate that a pure continuous Galerkin scheme is indeed linearly stable if the boundary conditions are imposed in the correct way. In this work, we extend this investigation to the nonlinear case and focus on entropy conservation. Here, by switching to entropy variables, we provide an estimation of the boundary operators also for nonlinear problems, that guarantee conservation. In numerical simulations, we verify our theoretical analysis.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

A Comprehensive Review on Finite Element Analysis of Laser Shock Peening

Laser shock peening (LSP) is a formidable cold working surface treatment that provides high-energy precision to enhance the mechanical properties of materials. This paper delves into the intricacies of the LSP process, offering insights into its methodology and the simulation thereof through the finite element method. This review critically examines various points, such as laser energy, overlapping of shots, effect of LSP on residual stress, effect of LSP on grain refinement, and algorithms for simulation extrapolated from finite element analyses conducted by researchers, shedding light on the nuanced considerations integral to this technique. As the significance of LSP continues to grow, the collective findings underscore its potential as a transformative technology for fortifying materials against mechanical stress and improving their overall performance and longevity. The discourse encapsulates the evolving landscape of the LSP, emphasizing the pivotal role played by finite element analysis in advancing our understanding and application of this innovative surface treatment.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Integrated thermal-structural analysis of large space structures

Optimum performance of large space antennas requires very fine control of the shape of the antenna surface since the shape affects both frequency control and pointing accuracy. A significant factor affecting the antenna shape is the temperature of the structure and the resulting deformation. To accurately predict the temperature of the structure, it is necessary first to accurately predict thermal loads. As the structure orbits the Earth, the thermal loads change constantly so that the thermal-structural response varies continuously throughout the orbit. The results from recent applications of integrated finite element methodology to heat load determination and thermal-structural analysis of large space structures are given. Four areas are concentrated on: (1) the characteristics of the integrated finite element methodology, (2) fundamentals of orbital heat load calculation, (3) description and comparison of some radiation finite elements, and (4) application of the integrated finite-element approach to the thermal-structural analysis of an orbiting truss structure.

Mahaney, J.↗
NASA NTRS1989

Notched fatigue of single crystal PWA 1480 at turbine attachment temperatures

The focus is on the lower temperature, uncoated and notched features of gas turbine blades. Constitutive and fatigue life prediction models applicable to these regions are being developed. Fatigue results are presented which were obtained thus far. Fatigue tests are being conducted on PWA 1480 single crystal material using smooth strain controlled specimens and three different notched specimens. Isothermal fatigue tests were conducted at 1200, 1400, and 1600 F. The bulk of the tests were conducted at 1200 F. The strain controlled tests were conducted at 0.4 percent per second strain rate and the notched tests were cycled at 1.0 cycle per second. A clear orientation dependence is observed in the smooth strain controlled fatigue results. The fatigue lifes of the thin, mild notched specimens agree fairly well with this smooth data when elastic stress range is used as a correlating parameter. Finite element analyses were used to calculate notch stresses. Fatigue testing will continue to further explore the trends observed thus far. Constitutive and life prediction models are being developed.

Meyer, T. G.↗
NASA NTRS1997

Nondestructive Evaluation of Adhesively Bonded Joints

The final report consists of 5 published papers in referred journals and a technical letter to the technical monitor. These papers include the following: (1) Comparison of the effects of debonds and voids in adhesive; (2) On the peak shear stresses in adhesive joints with voids; (3) Nondestructive evaluation of adhesively bonded joints by acousto-ultrasonic technique and acoustic emission; (4) Multiaxial fatigue life evaluation of tubular adhesively bonded joints; (5) Theoretical and experimental evaluation of the bond strength under peeling loads. The letter outlines the progress of the research. Also included is preliminary information on the study of nondestructive evaluation of composite materials subjected to localized heat damage. The investigators studied the effects of localized heat on unidirectional fiber glass epoxy composite panels. Specimens of the fiber glass epoxy composites were subjected to 400 C heat for varying lengths of time. The specimens were subjected to nondestructive tests. The specimens were then pulled to their failure and acoustic emission of these specimens were measured. The analysis of the data was continuing as of the writing of the letter, and includes a finite element stress analysis of the problem.

Nayeb-Hashemi, Hamid↗
NASA NTRS2009

Refined Zigzag Theory for Laminated Composite and Sandwich Plates

A refined zigzag theory is presented for laminated-composite and sandwich plates that includes the kinematics of first-order shear deformation theory as its baseline. The theory is variationally consistent and is derived from the virtual work principle. Novel piecewise-linear zigzag functions that provide a more realistic representation of the deformation states of transverse-shear-flexible plates than other similar theories are used. The formulation does not enforce full continuity of the transverse shear stresses across the plate s thickness, yet is robust. Transverse-shear correction factors are not required to yield accurate results. The theory is devoid of the shortcomings inherent in the previous zigzag theories including shear-force inconsistency and difficulties in simulating clamped boundary conditions, which have greatly limited the accuracy of these theories. This new theory requires only C(sup 0)-continuous kinematic approximations and is perfectly suited for developing computationally efficient finite elements. The theory should be useful for obtaining relatively efficient, accurate estimates of structural response needed to design high-performance load-bearing aerospace structures.

Tessler, Alexander↗
DOE OSTI2023

Bound-preserving finite element approximations of the Keller–Segel equations

We report this paper aims to develop numerical approximations of the Keller–Segel equations that mimic at the discrete level the lower bounds and the energy law of the continuous problem. We solve these equations for two unknowns: the organism (or cell) density, which is a positive variable, and the chemoattractant density, which is a non-negative variable. We propose two algorithms, which combine a stabilized finite element method and a semi-implicit time integration. The stabilization consists of a nonlinear artificial diffusion that employs a graph-Laplacian operator and a shock detector that localizes local extrema. As a result, both algorithms turn out to be nonlinear and can generate cell and chemoattractant numerical densities fulfilling lower bounds. However, the first algorithm requires a suitable constraint between the space and time discrete parameters, whereas the second one does not. We design the latter to attain a discrete energy law on acute meshes. We report some numerical experiments to validate the theoretical results on blowup and nonblowup phenomena. In the blowup setting, we identify a locking phenomenon that relates the L ∞ (Ω)-norm to the L 1 (Ω)-norm limiting the growth of the singularity when supported on a macroelement.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1992

Application of edge-based finite elements and vector ABCs in 3D scattering

A finite element absorbing boundary condition (FE-ABC) solution of the scattering by arbitrary 3-D structures is considered. The computational domain is discretized using edge-based tetrahedral elements. In contrast to the node-based elements, edge elements can treat geometries with sharp edges, are divergence-less, and easily satisfy the field continuity condition across dielectric interfaces. They do, however, lead to a higher unknown count but this is balanced by the greater sparsity of the resulting finite element matrix. Thus, the computation time required to solve such a system iteratively with a given degree of accuracy is less than the traditional node-based approach. The purpose is to examine the derivation and performance of the ABC's when applied to 2-D and 3-D problems and to discuss the specifics of our FE-ABC implementation.

Chatterjee, A.↗
DOE OSTI2022

Efficient co-solution of time step size and independent state in simulations of fluid-driven fracture propagation with embedded meshes

Here we present an efficient time-continuation scheme for fluid-driven fracture propagation problems in the extended finite element method framework. The approach applies a monolithic solution strategy to a fully coupled and implicit approximation of hydro-mechanical systems in conjunction with simultaneous linear elastic propagation of multiple fractures. At the end of each time step, the process ensures that the weakest fracture tip is in an equilibrium propagation regime. Furthermore, the solution process provides an initialization procedure for the newly created fracture spaces and an a priori estimate of the stress intensity factor growth rate, improving simulation robustness, and efficiency. The solution process is validated using the Kristianovich-Geertsma-de Klerk analytical solution under the toughness- and viscosity-dominated regimes. It is also extended to and demonstrated on problems with multiple fractures undergoing simultaneous propagation with stress shadow interactions. Numerical examples demonstrate that the solution process can reduce the required computational cost by one order of magnitude compared to other existing methods.

42 ENGINEERING↗
DOE OSTI2024

A phase-field diffraction model for thermo-hydro-mechanical propagating fractures

This paper introduces a novel diffraction based thermo-hydraulic–mechanical (THM) model for fracture propagation using a phase-field fracture (PFF) approach. The key innovation of the THM-PFF model lies in its integrated treatment of four solution variables—displacements, phase-field, pressure, and temperature—each governed by a combination of conservation of momentum (mechanics problem), a variational inequality (constrained minimization problem), mass conservation (pressure problem), and energy conservation (temperature problem). This leads to a new formulation of a coupled variational inequality system. A major advancement is the development of an extended fixed-stress algorithm, where displacements, phase-field, pressures, and temperatures are solved in a staggered sequence. An important aspect of this work is the global coupling of pressures and temperatures across the domain using diffraction systems, with diffraction coefficients defined by material parameters weighted by the diffusive phase-field variable. To ensure robust local mass conservation, we employ enriched Galerkin finite elements (EG) for both pressure and temperature diffraction equations. By enriching the continuous Galerkin basis functions with discontinuous piecewise constants, EG accurately represents solution and parameter discontinuities while preserving local mass and energy conservation—crucial aspects for THM problems and realistic behavior. Moreover, the use of a predictor–corrector local mesh adaptivity scheme is employed, allowing the model to handle small phase-field length-scale parameters while maintaining high numerical accuracy and reasonable computational cost. Furthermore, these new model and algorithmic developments represent significant advances in the field and have been substantiated through rigorous numerical tests.

Diffraction systems↗
NASA NTRS1982

A viscous-inviscid interaction algorithm for three-dimensional turbulent subsonic aerodynamic juncture region flow

An order-of magnitude analysis of the subsonic, three-dimensional, steady time-averaged Navier-Stokes equations for semibounded aerodynamic juncture geometries yields the parabolic Navier-Stokes simplification. The numerical solution of the resultant pressure Poisson equation is cast into complementary and particular parts, yielding an iterative interaction algorithm with an exterior three-dimensional potential flow solution. A parabolic transverse momentum equation set is constructed, wherein robust enforcement first-order continuity effects is accomplished using a penalty differential constraint concept within a finite element solution algorithm. A Reynolds stress constitutive equation, with low turbulence Reynolds number wall functions, is employed for closure, using parabolic forms of the two-equation turbulent kinetic energy-dissipation equation system. The algorithm is employed to predict the three-dimensional turbulent flowfield in the juncture region formed by two intersecting parabolic arcs at a free-stream Mach-number of 0.08, and Re/C = 600,000/m.

Baker, A. J.↗
NASA NTRS1982

The CMC:3DPNS computer program for prediction of three-dimensional, subsonic, turbulent aerodynamic juncture region flow. Volume 1: Theoretical

An order-of-magnitude analysis of the subsonic three dimensional steady time averaged Navier-Stokes equations, for semibounded aerodynamic juncture geometries, yields the parabolic Navier-Stokes simplification. The numerical solution of the resultant pressure Poisson equation is cast into complementary and particular parts, yielding an iterative interaction algorithm with an exterior three dimensional potential flow solution. A parabolic transverse momentum equation set is constructed, wherein robust enforcement of first order continuity effects is accomplished using a penalty differential constraint concept within a finite element solution algorithm. A Reynolds stress constitutive equation, with low turbulence Reynolds number wall functions, is employed for closure, using parabolic forms of the two-equation turbulent kinetic energy-dissipation equation system. Numerical results document accuracy, convergence, and utility of the developed finite element algorithm, and the CMC:3DPNS computer code applied to an idealized wing-body juncture region. Additional results document accuracy aspects of the algorithm turbulence closure model.

Baker, A. J.↗
NASA NTRS1982

Benchmark notch test for life prediction

The laser Interferometric Strain Displacement Gage (ISDG) was used to measure local strains in notched Inconel 718 test bars subjected to six different load histories at 649 C (1200 F) and including effects of tensile and compressive hold periods. The measurements were compared to simplified Neuber notch analysis predictions of notch root stress and strain. The actual strains incurred at the root of a discontinuity in cyclically loaded test samples subjected to inelastic deformation at high temperature where creep deformations readily occur were determined. The steady state cyclic, stress-strain response at the root of the discontinuity was analyzed. Flat, double notched uniaxially loaded fatigue specimens manufactured from the nickel base, superalloy Inconel 718 were used. The ISDG was used to obtain cycle by cycle recordings of notch root strain during continuous and hold time cycling at 649 C. Comparisons to Neuber and finite element model analyses were made. The results obtained provide a benchmark data set in high technology design where notch fatigue life is the predominant component service life limitation.

Domas, P. A.↗