9 research outputs found
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Adhesive Joint and Composites Modeling in SIERRA
Polymers and fiber-reinforced polymer matrix composites play an important role in many Defense Program applications. Recently an advanced nonlinear viscoelastic model for polymers has been developed and incorporated into ADAGIO, Sandia's SIERRA-based quasi-static analysis code. Standard linear elastic shell and continuum models for fiber-reinforced polymer-matrix composites have also been added to ADAGIO. This report details the use of these models for advanced adhesive joint and composites simulations carried out as part of an Advanced Simulation and Computing Advanced Deployment (ASC AD) project. More specifically, the thermo-mechanical response of an adhesive joint when loaded during repeated thermal cycling is simulated, the response of some composite rings under internal pressurization is calculated, and the performance of a composite container subjected to internal pressurization, thermal loading, and distributed mechanical loading is determined. Finally, general comparisons between the continuum and shell element approaches for modeling composites using ADAGIO are given
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A mechanism-based approach to modeling ductile fracture.
Ductile fracture in metals has been observed to result from the nucleation, growth, and coalescence of voids. The evolution of this damage is inherently history dependent, affected by how time-varying stresses drive the formation of defect structures in the material. At some critically damaged state, the softening response of the material leads to strain localization across a surface that, under continued loading, becomes the faces of a crack in the material. Modeling localization of strain requires introduction of a length scale to make the energy dissipated in the localized zone well-defined. In this work, a cohesive zone approach is used to describe the post-bifurcation evolution of material within the localized zone. The relations are developed within a thermodynamically consistent framework that incorporates temperature and rate-dependent evolution relationships motivated by dislocation mechanics. As such, we do not prescribe the evolution of tractions with opening displacements across the localized zone a priori. The evolution of tractions is itself an outcome of the solution of particular, initial boundary value problems. The stress and internal state of the material at the point of bifurcation provides the initial conditions for the subsequent evolution of the cohesive zone. The models we develop are motivated by in-situ scanning electron microscopy of three-point bending experiments using 6061-T6 aluminum and 304L stainless steel, The in situ observations of the initiation and evolution of fracture zones reveal the scale over which the failure mechanisms act. In addition, these observations are essential for motivating the micromechanically-based models of the decohesion process that incorporate the effects of loading mode mixity, temperature, and loading rate. The response of these new cohesive zone relations is demonstrated by modeling the three-point bending configuration used for the experiments. In addition, we survey other methods with the potential to provide more detailed information about the near tip deformation fields
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Progress report for the ASCI AD resistance weld process modeling project AD2003-15.
This report documents activities related to the ASCI AD Resistance Weld Process Modeling Project AD2003-15. Activities up to and including FY2004 are discussed. This was the third year for this multi year project, the objective of which is to position the SIERRA computational tools for the solution of resistance welding problems. The process of interest is a three-way coupled problem involving current flow, temperature buildup and large plastic deformation. The DSW application is the reclamation stem weld used in the manufacture of high pressure gas bottles. This is the first year the CALAGIO suite of codes (eCALORE, CALORE, and ADAGIO) was used to successfully solve a three-way coupled problem in SIERRA. This report discusses the application of CALAGIO to the tapered bar acceptance problem and a similar but independent tapered bar simulation of a companion C6 experiment. New additions to the EMMI constitutive model and issues related to CALAGIO performance are also discussed
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Quantifying the debonding of inclusions through tomography and computational homology.
This report describes a Laboratory Directed Research and Development (LDRD) project to use of synchrotron-radiation computed tomography (SRCT) data to determine the conditions and mechanisms that lead to void nucleation in rolled alloys. The Advanced Light Source (ALS) at Lawrence Berkeley National Laboratory (LBNL) has provided SRCT data of a few specimens of 7075-T7351 aluminum plate (widely used for aerospace applications) stretched to failure, loaded in directions perpendicular and parallel to the rolling direction. The resolution of SRCT data is 900nm, which allows elucidation of the mechanisms governing void growth and coalescence. This resolution is not fine enough, however, for nucleation. We propose the use statistics and image processing techniques to obtain sub-resolution scale information from these data, and thus determine where in the specimen and when during the loading program nucleation occurs and the mechanisms that lead to it. Quantitative analysis of the tomography data, however, leads to the conclusion that the reconstruction process compromises the information obtained from the scans. Alternate, more powerful reconstruction algorithms are needed to address this problem, but those fall beyond the scope of this project
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Microstructure-based approach for predicting crack initiation and early growth in metals.
Fatigue cracking in metals has been and is an area of great importance to the science and technology of structural materials for quite some time. The earliest stages of fatigue crack nucleation and growth are dominated by the microstructure and yet few models are able to predict the fatigue behavior during these stages because of a lack of microstructural physics in the models. This program has developed several new simulation tools to increase the microstructural physics available for fatigue prediction. In addition, this program has extended and developed microscale experimental methods to allow the validation of new microstructural models for deformation in metals. We have applied these developments to fatigue experiments in metals where the microstructure has been intentionally varied
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Predicting fracture in micron-scale polycrystalline silicon MEMS structures.
Designing reliable MEMS structures presents numerous challenges. Polycrystalline silicon fractures in a brittle manner with considerable variability in measured strength. Furthermore, it is not clear how to use a measured tensile strength distribution to predict the strength of a complex MEMS structure. To address such issues, two recently developed high throughput MEMS tensile test techniques have been used to measure strength distribution tails. The measured tensile strength distributions enable the definition of a threshold strength as well as an inferred maximum flaw size. The nature of strength-controlling flaws has been identified and sources of the observed variation in strength investigated. A double edge-notched specimen geometry was also tested to study the effect of a severe, micron-scale stress concentration on the measured strength distribution. Strength-based, Weibull-based, and fracture mechanics-based failure analyses were performed and compared with the experimental results
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Measurement and interpretation of threshold stress intensity factors for steels in high-pressure hydrogen gas.
Threshold stress intensity factors were measured in high-pressure hydrogen gas for a variety of low alloy ferritic steels using both constant crack opening displacement and rising crack opening displacement procedures. The sustained load cracking procedures are generally consistent with those in ASME Article KD-10 of Section VIII Division 3 of the Boiler and Pressure Vessel Code, which was recently published to guide design of high-pressure hydrogen vessels. Three definitions of threshold were established for the two test methods: K{sub THi}* is the maximum applied stress intensity factor for which no crack extension was observed under constant displacement; K{sub THa} is the stress intensity factor at the arrest position for a crack that extended under constant displacement; and K{sub JH} is the stress intensity factor at the onset of crack extension under rising displacement. The apparent crack initiation threshold under constant displacement, K{sub THi}*, and the crack arrest threshold, K{sub THa}, were both found to be non-conservative due to the hydrogen exposure and crack-tip deformation histories associated with typical procedures for sustained-load cracking tests under constant displacement. In contrast, K{sub JH}, which is measured under concurrent rising displacement and hydrogen gas exposure, provides a more conservative hydrogen-assisted fracture threshold that is relevant to structural components in which sub-critical crack extension is driven by internal hydrogen gas pressure
Ductile failure X-prize.
Fracture or tearing of ductile metals is a pervasive engineering concern, yet accurate prediction of the critical conditions of fracture remains elusive. Sandia National Laboratories has been developing and implementing several new modeling methodologies to address problems in fracture, including both new physical models and new numerical schemes. The present study provides a double-blind quantitative assessment of several computational capabilities including tearing parameters embedded in a conventional finite element code, localization elements, extended finite elements (XFEM), and peridynamics. For this assessment, each of four teams reported blind predictions for three challenge problems spanning crack initiation and crack propagation. After predictions had been reported, the predictions were compared to experimentally observed behavior. The metal alloys for these three problems were aluminum alloy 2024-T3 and precipitation hardened stainless steel PH13-8Mo H950. The predictive accuracies of the various methods are demonstrated, and the potential sources of error are discussed