ALBERT

Description: For an individual participant data (IPD) meta-analysis, multiple datasets must be transformed in a consistent format, e.g. using uniform variable names. When large numbers of datasets have to be processed, thi...

Description: Additive manufacturing (AM) process methods such as powder bed fusion (LPBF) of metal powder layers can produce layered material systems with designed microstructures, which may exhibit scatter in mechanical properties (e.g., lower yield and lower failure strain), corrosion due to porosity and print anomalies. This study shows the development of AM process simulation to predict As-built material characteristic and their scatter comparing with experimental test data. ICME (Integrated Computational Materials Engineering) was used to simulate yield, ultimate, strain, and reduction of the area of sample AM. The method was extended to predict oxidation and damage of as-built parts. The samples were fabricated horizontally and vertically in multiple and scatter directions to find the effect on the mechanical properties such as ultimate tensile strength (UTS) and yield strength (YS). The probabilistic sensitivities show that in order for the next-generation technology to improve the strength of 3D printed materials, they must control the void volume fraction (trapped gas) and orientation of voids. The studied 3D print modality processes: (a) LPBF of AlSi10Mg, and (b) Electron Beam (EBM) of Ti-6Al-4V materials are shown to be over 99.99% reliable. The statistics of 3D printed Ti-6Al-4V have been observed for room and high temperature (RT/HT). The ICME Material Characterization and Qualification (MCQ) software material model prediction capabilities were used to predict (a) Material Allowable, a variation in Stress Strain Curves Characteristic Points and Residual Stress due to air particle (void/defect) shape and size and orientation. The probabilistic simulation computes Cumulative Distribution Function (CDF) and probabilistic sensitivities for YS, UTS, and %Elongation as well as A and B basis allowable of the As-Built 3D printed material and; and (b) Fracture Control Plan fracture toughness determination, and fatigue crack growth vs. stress intensity.

Description: This document presents in viewgraph form techniques for the optimal design of aerospace vehicles which take into account vehicle shape, aerodynamic performance, and weight minimization. Methods include multilevel optimization with linear decomposition, multi-constraint optimization, global sensitivity matrix, and calculation of sensitivity derivatives using both first and second order derivatives. The effects of including flexibility in the optimization is discussed.

Description: The wide spectrum of needs and applications are demonstrated of computational structural mechanics. The spectrum ranges from micro structural mechanics to the optimization of the performance of aerovehicles. Critical high leveraged technologies will require engineering process modernization and automation, affordable structures and materials, and advanced computational technology. Recent advances at Rockwell International in computational structural mechanics addressed these issues and improve the ability to achieve advanced aircraft objectives.

Description: An integrally stiffened graphite/epoxy composite rotorcraft structure is evaluated via computational simulation. A computer code that scales up constituent micromechanics level material properties to the structure level and accounts for all possible failure modes is used for the simulation of composite degradation under loading. Damage initiation, growth, accumulation, and propagation to fracture are included in the simulation. Design implications with regard to defect and damage tolerance of integrally stiffened composite structures are examined. A procedure is outlined regarding the use of this type of information for setting quality acceptance criteria, design allowables, damage tolerance, and retirement-for-cause criteria.

Description: A computational structural/material analysis and design tool which would meet industry's future demand for expedience and reduced cost is presented. This unique software 'GENOA' is dedicated to parallel and high speed analysis to perform probabilistic evaluation of high temperature composite response of aerospace systems. The development is based on detailed integration and modification of diverse fields of specialized analysis techniques and mathematical models to combine their latest innovative capabilities into a commercially viable software package. The technique is specifically designed to exploit the availability of processors to perform computationally intense probabilistic analysis assessing uncertainties in structural reliability analysis and composite micromechanics. The primary objectives which were achieved in performing the development were: (1) Utilization of the power of parallel processing and static/dynamic load balancing optimization to make the complex simulation of structure, material and processing of high temperature composite affordable; (2) Computational integration and synchronization of probabilistic mathematics, structural/material mechanics and parallel computing; (3) Implementation of an innovative multi-level domain decomposition technique to identify the inherent parallelism, and increasing convergence rates through high- and low-level processor assignment; (4) Creating the framework for Portable Paralleled architecture for the machine independent Multi Instruction Multi Data, (MIMD), Single Instruction Multi Data (SIMD), hybrid and distributed workstation type of computers; and (5) Market evaluation. The results of Phase-2 effort provides a good basis for continuation and warrants Phase-3 government, and industry partnership.

Description: A decomposition and multidisciplinary optimization methodology for aircraft design is presented, based on multilevel optimization and use of global sensitivity equations to account for interdisciplinary effects. A brief study of a hypersonic cruise vehicle is developed to illustrate methodology. The vehicle is sized for minimum take-off gross weight considering aerodynamics, structures, and mission performance.

Description: S-Glass/epoxy laminated fiber-reinforced composite stiffened plate structure with laminate configuration (0/90)5 was simulated to investigate damage and fracture progression, under uniform pressure. For comparison reasons a simple plate was examined, in addition with the stiffened plate. An integrated computer code was used for the simulation. The damage initiation began with matrix failure in tension, continuous with damage and/or fracture progression as a result of additional matrix failure and fiber fracture and followed by additional interply delamination. Fracture through the thickness began when the damage accumulation was 90%. After that stage, the cracks propagate rapidly and the structures collapse. The collapse load for the simple plate is 21.57 MPa (3120 psi) and for the stiffened plate 25.24 MPa (3660 psi).

Description: A capability consisting of software development and experimental techniques has been developed and is described. The capability is integrated into GENOA-PFA to model polymer matrix composite (PMC) structures. The capability considers the physics and mechanics of composite materials and structure by integration of a hierarchical multilevel macro-scale (lamina, laminate, and structure) and micro scale (fiber, matrix, and interface) simulation analyses. The modeling involves (1) ply layering methodology utilizing FEM elements with through-the-thickness representation, (2) simulation of effects of material defects and conditions (e.g., voids, fiber waviness, and residual stress) on global static and cyclic fatigue strengths, (3) including material nonlinearities (by updating properties periodically) and geometrical nonlinearities (by Lagrangian updating), (4) simulating crack initiation. and growth to failure under static, cyclic, creep, and impact loads. (5) progressive fracture analysis to determine durability and damage tolerance. (6) identifying the percent contribution of various possible composite failure modes involved in critical damage events. and (7) determining sensitivities of failure modes to design parameters (e.g., fiber volume fraction, ply thickness, fiber orientation. and adhesive-bond thickness). GENOA-PFA progressive failure analysis is now ready for use to investigate the effects on structural responses to PMC material degradation from damage induced by static, cyclic (fatigue). creep, and impact loading in 2D/3D PMC structures subjected to hygrothermal environments. Its use will significantly facilitate targeting design parameter changes that will be most effective in reducing the probability of a given failure mode occurring.