Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 C to an ambient temperature of 23 C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC

Merging Cellular Automata for Simulating Surface Effects

International audienceThis paper describes a model of three-dimensional cellular automata allowing to simulate different phenomena in the fields of com- puter graphics and image processing, and to combine them together in order to produce complex effects such as automatic multitexturing, sur- face imperfections, or biological retina multi-layer cellular behaviours. Our cellular automaton model is defined as a network of connected cells arranged in a natural and dynamic way, which affords multi-behavior ca- pabilities. Based on cheap and widespread computing systems, real-time performance can be reached for simulations involving up to a hundred thousand cells. Our approach efficiency is illustrated through a set of CA related to computer graphics –e.g. erosion, sedimentation, or vegetal growing processes– and image analysis –e.g. pipeline retina simulation

Modeling and Simulation of a Robotic Bridge Inspection System

Inspection and preservation of the aging bridges to extend their service life has been recognized as one of the important tasks of the State Departments of Transportation. Yet manual inspection procedure is not efficient to determine the safety status of the bridges in order to facilitate the implementation of appropriate maintenance. In this paper, a complex model involving a remotely controlled robotic platform is proposed to inspect the safety status of the bridges which will eliminate labor-intensive inspection. Mobile cameras from unmanned airborne vehicles (UAV) are used to collect bridge inspection data in order to record the periodic changes of bridge components. All the UAVs are controlled via a control station and continuously feed image data to a deep learning-based detection algorithm to analyze the data to detect critical structural components. A cellular automata-based pattern recognition algorithm is used to find the pattern of structural damage. A simulation model is developed to validate the proposed method by knowing the frequency and time required for each task involved in bridge inspection and maintenance. The effectiveness of the model is demonstrated by simulating the bridge inspection and maintenance with the proposed model for five years in AnyLogic. The simulated result shows around 80% of man-hour can be saved with the proposed approach

Example-Based Fractured Appearance

International audienceA common weathering effect is the appearance of cracks due to material fractures. Previous exemplar-based aging and weathering methods have either reused images or sought to replicate observed patterns exactly. We introduce a new approach to exemplar-based modeling that creates weathered patterns on synthetic objects by matching the statistics of fracture patterns in a photograph. We present a user study to determine which statistics are correlated to visual similarity and how they are perceived by the user. We then describe a revised physically-based fracture model capable of producing a wide range of crack patterns at interactive rates. We demonstrate how a Bayesian optimization method can determine the parameters of this model so it can produce a pattern with the same key statistics as an exemplar. Finally, we present results using our approach and various exemplars to produce a variety of fracture effects in synthetic renderings of complex environments. The speed of the fracture simulation allows interactive previews of the fractured results and its application on large scale environments

Real-time hybrid cutting with dynamic fluid visualization for virtual surgery

It is widely accepted that a reform in medical teaching must be made to meet today's high volume training requirements. Virtual simulation offers a potential method of providing such trainings and some current medical training simulations integrate haptic and visual feedback to enhance procedure learning. The purpose of this project is to explore the capability of Virtual Reality (VR) technology to develop a training simulator for surgical cutting and bleeding in a general surgery

Solidification in laser powder deposition of Ti-Nb alloys

The size and morphology of the dendrite growth patterns are simulated for laser powder deposition of Ti-Nb alloys under steady-state and transient growth conditions. A phase field model using an adaptive grid technique was employed to simulate the steady-state growth of dendrites on rather small domains, in which fixed local solidification conditions are present. For simulation of dendrite growth patterns at transient conditions, a cellular automaton model was used along with a virtual front tracking technique on larger domains, containing various initial orientations of the solid-liquid (SL) interface. To obtain the required input thermal data, i.e., the temporal distribution of temperature, a finite element analysis was performed along with a novel numerical approach for the real-time addition of new deposition material in each time step, thus building the deposition geometry momentarily. Using the output of the thermal model, the motion and morphology of the SL interface was determined through tracking the isotherm of the solidification temperature. First, in this study, the appropriate set of processing parameters was found through an optimization process using a new concept, laser supplied energy Es, which combines the effects of the energy and powder density in the process. With the developed analytical/experimental procedure, crack and pore-free coatings of Ti-Nb with continuous beads were produced by examining the effects of a few sets of processing parameters, including laser power, laser scan velocity, laser beam diameter and powder feed rate. The results of the thermal model for the optimized set of parameters matched with the thermocouple temperature measurements with only ~5% deviation. The thermal model was able to predict realistic profiles for the temporal development of deposition geometry, thus predicting meaningful morphologies of the SL interface. The model output was easily treated for extraction of local processing parameters, such as the temperature gradient and solidification velocity. These data are very useful when simulating the dendrite growth patterns at steady-state conditions in directional solidification of selected regions in the microstructure. In order to define transient growth conditions, the simulated distribution of temperature can be also directly fed into the microstructure model at each solution time step. Phase field simulations of steady-state growth of dendrites during directional solidification showed a remarkable agreement with the experimental observations for the local dendrite arm spacing across the microstructure. Also qualitatively agreeing with the experiment, the simulated dendrite spacing exhibited a minimum around the mid-height region of the microstructure, which is explained by the counter effect of the temperature gradient and solidification velocity along the height of the sample. On a large domain containing different initial orientations of the SL interface, cellular automaton simulations for transient growth patterns of dendrites could reproduce most qualitative features observed in the microstructure. The dendrite arm spacing gradually decreased from the top of the microstructure. The competition was won by the dendrites growing in areas with higher cooling rates, i.e., in the regions closer to the top of the microstructure. The secondary arms of the primary dendrites, which are initially inclined on the vertical axis, grew extensively only along the overall growth direction and eventually became primary arms in some cases

Numerical modelling of the aluminium extrusion process

The extrusion of aluminium alloys involves the shaping of the product from an homogenised billet into a complex shape. In addition the properties of the extrudate are closely related to the processing parameters (temperature, stain rate, and material morphology). Since all the parameters vary throughout the ram stroke and throughout the billet the prediction of the condition of the extrudate is complex. In this study the analysis is accomplished by the use of finite element analysis coupled with sub-illodelling of the structural features. The study is extended to include the lieat-treatment process necessary for precipitation hardened alloys subsequent to the process. The author has published these results in a number of learned journals and these are given in Appendix. After a concise introduction and crirical literature review chapter3 analyses the basic operation of the finite element package(FEM) discussing the procedures involved, the equilibrium equations and the more practical aspect of the mesh morphology and size. Finite Element analysis and material structural models have been integrated using parallel processing technology and program sub-routines. In this section the external inputs are also defined paying particular attention to the friction conditions and the constitutive equations. The thesis then proceeds to describe and analyse the integrated modelling of the process necessary to introduce the user introduction of the equations necessary to produce a comprehensive analysis of the material structural problems. This includes the cellular automata teclu-iiques. Various complex extrusion geometries are analysed and the effects of scaling considered. Development of the extrudate surface and criteria for ptedicting this important feature are coinprehebsivcly covered in chapter 5 whilst chapter 6 considers some special technologies such as the use of pockets to obtain homogenous structures. Isothermal extrusion is also included in this section