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- Creators: Arizona State University
- Creators: Mobasher, Barzin
Description
Advanced fibrous composite materials exhibit outstanding thermomechanical performance under extreme environments, which make them ideal for structural components that are used in a wide range of aerospace, nuclear, and defense applications. The integrity and residual useful life of these components, however, are strongly influenced by their inherent material flaws and defects resulting from the complex fabrication processes. These defects exist across multiple length scales and govern several scale-dependent inelastic deformation mechanisms of each of the constituents as well as their composite damage anisotropy. Tailoring structural components for optimal performance requires addressing the knowledge gap regarding the microstructural material morphology that governs the structural scale damage and failure response. Therefore, there is a need for a high-fidelity multiscale modeling framework and scale-specific in-situ experimental characterization that can capture complex inelastic mechanisms, including damage initiation and propagation across multiple length scales. This dissertation presents a novel multiscale computational framework that accounts for experimental information pertinent to microstructure morphology and architectural variabilities to investigate the response of ceramic matrix composites (CMCs) with manufacturing-induced defects. First, a three-dimensional orthotropic viscoplasticity creep formulation is developed to capture the complex temperature- and time-dependent constituent load transfer mechanisms in different CMC material systems. The framework also accounts for a reformulated fracture mechanics-informed matrix damage model and the Curtin progressive fiber damage model to capture the complex scale-dependent damage and failure mechanisms through crack kinetics and porosity growth. Next, in-situ experiments using digital image correlation (DIC) are performed to capture the damage and failure mechanisms in CMCs and to validate the high-fidelity modeling results.
The dissertation also presents an exhaustive experimental investigation into the effects of temperature and manufacturing-induced defects on toughened epoxy adhesives and hybrid composite-metallic bonded joints. Nondestructive evaluation techniques are utilized to characterize the inherent defects morphology of the bulk adhesives and bonded interface. This is followed by quasi-static tensile tests conducted at extreme hot and cold temperature conditions. The damage mechanisms and failure modes are investigated using in-situ DIC and a high-resolution camera. The information from the morphology characterization studies is used to reconstruct high-fidelity geometries of the test specimens for finite element analysis.
ContributorsKhafagy, Khaled Hassan Abdo (Author) / Chattopadhyay, Aditi (Thesis advisor) / Fard, Masoud Y. (Committee member) / Milcarek, Ryan (Committee member) / Stoumbos, Tom (Committee member) / Borkowski, Luke (Committee member) / Arizona State University (Publisher)
Created2022
Description
The ironmaking process involves the removal of oxygen atoms from the iron oxides to produce iron. Currently, the coal/coke-based blast furnace process dominates the industry with a 71% share of global steel production, making it responsible for 25% of total global industrial CO2 emissions. Several processes have been commercialized to reduce these CO2 emissions such as the direct reduction process which utilizes natural gas for energy and reducing agent. In the last few decades, H2 has been identified as an alternative reducing agent in place of coal and reformed natural gas for decarbonizing the ironmaking process.To commercialize the H2 direct reduction (H2DR) process, it is necessary to study this process on a laboratory, pilot, and industrial scale to identify and address the roadblocks in the path of commercialization. Based on the literature review performed in this dissertation, four knowledge gaps were identified, and hypotheses were formulated to address the same.
First, a numerical model was developed for a single iron ore pellet reduction process with a dynamic porosity function, and it was validated using experiments.
Second, the equation of the radius of pellet was derived as a function of the degree of reduction using experimental data to account for the shrinking and swelling.
Third, a numerical model was developed for a pilot scale H2DR reactor and was validated for average metallization of the pellets at the reactor outlet and the internal temperature profile in the reduction zone.
Fourth, the numerical model for the pilot scale H2DR reactor showed a gradient of metallization at the outlet boundary which was validated by experimental metallization analysis of 31 randomly selected pellet samples one by one.
At the end of the dissertation, the pilot scale model of the H2DR reactor was scaled up to an industrial scale with a DRI production capacity of 2.38 million tons/year approximately. The mass balance obtained from the industrial scale model was used to perform the techno-economic analysis to determine the economic implications of shifting from a 100% natural gas operation to a 100% H2 operation on an industrial scale.
ContributorsMeshram, Amogh Prashant (Author) / Seetharaman, Sridhar (Thesis advisor) / O'Malley, Ronald J (Committee member) / Nannenga, Brent L (Committee member) / Green, Matthew (Committee member) / Korobeinikov, Yuri (Committee member) / Arizona State University (Publisher)
Created2024
Description
Alkali activated mine tailing-slag blends and mine tailing-cement blends containing mine tailings as the major binder constituent are evaluated for their setting time behavior,
reactivity properties, flow characteristics, and compressive strengths. Liquid sodium
silicate and sodium hydroxide are used as the activator solution. The effects of varying
alkali oxide-to-powder ratio (n value) and silicon oxide-to-alkali oxide ratio (Ms value) is
explored. The reactivity of all blends prepared in this study is studied using an isothermal
calorimeter. Mine tailing-cement blends show a higher initial heat release peak than mine
tailing-slag blends, whereas their cumulative heat release is comparable for higher n values
of 0.050 to 0.100. Compressive strength tests and rheological studies were done for the
refined blends selected based on setting time criterion. Setting times and compressive
strengths are found to depend significantly on the activator parameters and binder
compositions, allowing fine-tuning of the mix proportion parameters based on the intended
end applications. The compressive strength of the selected mine tailing-slag blends and
mine tailing-cement blends are in the range of 7-40 MPa and 4-11 MPa, respectively.
Higher compressive strength is generally achieved at lower Ms and higher n values for mine
tailing-slag blends, while a higher Ms yields better compressive strength in the case of mine
tailing-cement blends. Rheological studies indicate a decrease in yield stress and viscosity
with increase in the replacement ratio, while a higher activator concentration increase both.
Oscillatory shear studies were used to evaluate the storage modulus and loss modulus of
the mine tailing binders. The paste is seen to exhibit a more elastic behavior at n values of
0.05 and 0.075, however the viscous behavior is seen to dominate at higher n value of 0.1
at similar replacement ratios and Ms value. A higher Ms value is also seen to increase the
onset point of the drop in both the storage and loss modulus of the pastes. The studied also
investigated the potential use of mine tailing blends for coating applications. The pastes
with higher alkalinity showed a lesser crack percentage, with a 10% slag replacement ratio
having a better performance compared to 20% and 30% slag replacement ratios. Overall,
the study showed that the activation parameters and mine tailings replacement level have
a significant influence on the properties of both mine tailing-slag binders and mine tailing-cement binders, thereby allowing selection of suitable mix design for the desired end
application, allowing a sustainable approach to dispose the mine tailings waste
ContributorsRamasamy Jeyaprakash, Rijul Kanth (Author) / Neithalath, Narayanan (Thesis advisor) / Rajan, Subramaniam (Committee member) / Mobasher, Barzin (Committee member) / Arizona State University (Publisher)
Created2023
Description
Weevils are among the most diverse and evolutionarily successful animal lineages on Earth. Their success is driven in part by a structure called the rostrum, which gives weevil heads a characteristic "snout-like" appearance. Nut weevils in the genus Curculio use the rostrum to drill holes into developing fruits and nuts, wherein they deposit their eggs. During oviposition this exceedingly slender structure is bent into a straightened configuration - in some species up to 90° - but does not suffer any damage during this process. The performance of the snout is explained in terms of cuticle biomechanics and rostral curvature, as presented in a series of four interconnected studies. First, a micromechanical constitutive model of the cuticle is defined to predict and reconstruct the mechanical behavior of each region in the exoskeleton. Second, the effect of increased endocuticle thickness on the stiffness and fracture strength of the rostrum is assessed using force-controlled tensile testing. In the third chapter, these studies are integrated into finite element models of the snout, demonstrating that the Curculio rostrum is only able to withstand repeated, extreme bending because of
modifications to the composite structure of the cuticle in the rostral apex. Finally, interspecific differences in the differential geometry of the snout are characterized to elucidate the role of biomechanical constraint in the evolution of rostral morphology for both males and females. Together these studies highlight the significance of cuticle biomechanics - heretofore unconsidered by others - as a source of constraint on the evolution of the rostrum and the mechanobiology of the genus Curculio.
modifications to the composite structure of the cuticle in the rostral apex. Finally, interspecific differences in the differential geometry of the snout are characterized to elucidate the role of biomechanical constraint in the evolution of rostral morphology for both males and females. Together these studies highlight the significance of cuticle biomechanics - heretofore unconsidered by others - as a source of constraint on the evolution of the rostrum and the mechanobiology of the genus Curculio.
ContributorsJansen, Michael Andrew (Author) / Franz, Nico M (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Harrison, Jon (Committee member) / Martins, Emilia (Committee member) / Arizona State University (Publisher)
Created2009
Description
The football helmet is a device used to help mitigate the occurrence of impact-related traumatic (TBI) and minor traumatic brain injuries (mTBI) in the game of American football. The current design methodology of using a hard shell with an energy absorbing liner may be adequate for minimizing TBI, however it has had less effect in minimizing mTBI. The latest research in brain injury mechanisms has established that the current design methodology has produced a helmet to reduce linear acceleration of the head. However, angular accelerations also have an adverse effect on the brain response, and must be investigated as a contributor of brain injury.
To help better understand how the football helmet design features effect the brain response during impact, this research develops a validated football helmet model and couples it with a full LS-DYNA human body model developed by the Global Human Body Modeling Consortium (v4.1.1). The human body model is a conglomeration of several validated models of different sections of the body. Of particular interest for this research is the Wayne State University Head Injury Model for modeling the brain. These human body models were validated using a combination of cadaveric and animal studies. In this study, the football helmet was validated by laboratory testing using drop tests on the crown of the helmet. By coupling the two models into one finite element model, the brain response to impact loads caused by helmet design features can be investigated. In the present research, LS-DYNA is used to study a helmet crown impact with a rigid steel plate so as to obtain the strain-rate, strain, and stress experienced in the corpus callosum, midbrain, and brain stem as these anatomical regions are areas of concern with respect to mTBI.
To help better understand how the football helmet design features effect the brain response during impact, this research develops a validated football helmet model and couples it with a full LS-DYNA human body model developed by the Global Human Body Modeling Consortium (v4.1.1). The human body model is a conglomeration of several validated models of different sections of the body. Of particular interest for this research is the Wayne State University Head Injury Model for modeling the brain. These human body models were validated using a combination of cadaveric and animal studies. In this study, the football helmet was validated by laboratory testing using drop tests on the crown of the helmet. By coupling the two models into one finite element model, the brain response to impact loads caused by helmet design features can be investigated. In the present research, LS-DYNA is used to study a helmet crown impact with a rigid steel plate so as to obtain the strain-rate, strain, and stress experienced in the corpus callosum, midbrain, and brain stem as these anatomical regions are areas of concern with respect to mTBI.
ContributorsDarling, Timothy (Author) / Rajan, Subramaniam D. (Thesis advisor) / Muthuswamy, Jitendran (Thesis advisor) / Oswald, Jay (Committee member) / Mignolet, Marc (Committee member) / Arizona State University (Publisher)
Created2014
Description
Laminated composite materials are used in aerospace, civil and mechanical structural systems due to their superior material properties compared to the constituent materials as well as in comparison to traditional materials such as metals. Laminate structures are composed of multiple orthotropic material layers bonded together to form a single performing part. As such, the layup design of the material largely influences the structural performance. Optimization techniques such as the Genetic Algorithm (GA), Differential Evolution (DE), the Method of Feasible Directions (MFD), and others can be used to determine the optimal laminate composite material layup. In this thesis, sizing, shape and topology design optimization of laminated composites is carried out. Sizing optimization, such as the layer thickness, topology optimization, such as the layer orientation and material and the number of layers present, and shape optimization of the overall composite part contribute to the design optimization process of laminates. An optimization host program written in C++ has been developed to implement the optimization methodology of both population based and numerical gradient based methods. The performance of the composite structural system is evaluated through explicit finite element analysis of shell elements carried out using LS-DYNA. Results from numerical examples demonstrate that optimization design processes can significantly improve composite part performance through implementation of optimum material layup and part shape.
ContributorsMika, Krista (Author) / Rajan, Subramaniam D. (Thesis advisor) / Neithalath, Narayanan (Committee member) / Mobasher, Barzin (Committee member) / Arizona State University (Publisher)
Created2014
Description
Composite materials are now beginning to provide uses hitherto reserved for metals in structural systems such as airframes and engine containment systems, wraps for repair and rehabilitation, and ballistic/blast mitigation systems. These structural systems are often subjected to impact loads and there is a pressing need for accurate prediction of deformation, damage and failure. There are numerous material models that have been developed to analyze the dynamic impact response of polymer matrix composites. However, there are key features that are missing in those models that prevent them from providing accurate predictive capabilities. In this dissertation, a general purpose orthotropic elasto-plastic computational constitutive material model has been developed to predict the response of composites subjected to high velocity impacts. The constitutive model is divided into three components – deformation model, damage model and failure model, with failure to be added at a later date. The deformation model generalizes the Tsai-Wu failure criteria and extends it using a strain-hardening-based orthotropic yield function with a non-associative flow rule. A strain equivalent formulation is utilized in the damage model that permits plastic and damage calculations to be uncoupled and capture the nonlinear unloading and local softening of the stress-strain response. A diagonal damage tensor is defined to account for the directionally dependent variation of damage. However, in composites it has been found that loading in one direction can lead to damage in multiple coordinate directions. To account for this phenomena, the terms in the damage matrix are semi-coupled such that the damage in a particular coordinate direction is a function of the stresses and plastic strains in all of the coordinate directions. The overall framework is driven by experimental tabulated temperature and rate-dependent stress-strain data as well as data that characterizes the damage matrix and failure. The developed theory has been implemented in a commercial explicit finite element analysis code, LS-DYNA®, as MAT213. Several verification and validation tests using a commonly available carbon-fiber composite, Toyobo’s T800/F3900, have been carried and the results show that the theory and implementation are efficient, robust and accurate.
ContributorsHoffarth, Canio (Author) / Rajan, Subramaniam D. (Thesis advisor) / Goldberg, Robert (Committee member) / Neithalath, Narayanan (Committee member) / Mobasher, Barzin (Committee member) / Liu, Yongming (Committee member) / Arizona State University (Publisher)
Created2016
Description
In material science, microstructure plays a key role in determining properties, which further determine utility of the material. However, effectively measuring microstructure evolution in real time remains an challenge. To date, a wide range of advanced experimental techniques have been developed and applied to characterize material microstructure and structural evolution on different length and time scales. Most of these methods can only resolve 2D structural features within a narrow range of length scale and for a single or a series of snapshots. The currently available 3D microstructure characterization techniques are usually destructive and require slicing and polishing the samples each time a picture is taken. Simulation methods, on the other hand, are cheap, sample-free and versatile without the special necessity of taking care of the physical limitations, such as extreme temperature or pressure, which are prominent
issues for experimental methods. Yet the majority of simulation methods are limited to specific circumstances, for example, first principle computation can only handle several thousands of atoms, molecular dynamics can only efficiently simulate a few seconds of evolution of a system with several millions particles, and finite element method can only be used in continuous medium, etc. Such limitations make these individual methods far from satisfaction to simulate macroscopic processes that a material sample undergoes up to experimental level accuracy. Therefore, it is highly desirable to develop a framework that integrate different simulation schemes from various scales
to model complicated microstructure evolution and corresponding properties. Guided by such an objective, we have made our efforts towards incorporating a collection of simulation methods, including finite element method (FEM), cellular automata (CA), kinetic Monte Carlo (kMC), stochastic reconstruction method, Discrete Element Method (DEM), etc, to generate an integrated computational material engineering platform (ICMEP), which could enable us to effectively model microstructure evolution and use the simulated microstructure to do subsequent performance analysis. In this thesis, we will introduce some cases of building coupled modeling schemes and present
the preliminary results in solid-state sintering. For example, we use coupled DEM and kinetic Monte Carlo method to simulate solid state sintering, and use coupled FEM and cellular automata method to model microstrucutre evolution during selective laser sintering of titanium alloy. Current results indicate that joining models from different length and time scales is fruitful in terms of understanding and describing microstructure evolution of a macroscopic physical process from various perspectives.
issues for experimental methods. Yet the majority of simulation methods are limited to specific circumstances, for example, first principle computation can only handle several thousands of atoms, molecular dynamics can only efficiently simulate a few seconds of evolution of a system with several millions particles, and finite element method can only be used in continuous medium, etc. Such limitations make these individual methods far from satisfaction to simulate macroscopic processes that a material sample undergoes up to experimental level accuracy. Therefore, it is highly desirable to develop a framework that integrate different simulation schemes from various scales
to model complicated microstructure evolution and corresponding properties. Guided by such an objective, we have made our efforts towards incorporating a collection of simulation methods, including finite element method (FEM), cellular automata (CA), kinetic Monte Carlo (kMC), stochastic reconstruction method, Discrete Element Method (DEM), etc, to generate an integrated computational material engineering platform (ICMEP), which could enable us to effectively model microstructure evolution and use the simulated microstructure to do subsequent performance analysis. In this thesis, we will introduce some cases of building coupled modeling schemes and present
the preliminary results in solid-state sintering. For example, we use coupled DEM and kinetic Monte Carlo method to simulate solid state sintering, and use coupled FEM and cellular automata method to model microstrucutre evolution during selective laser sintering of titanium alloy. Current results indicate that joining models from different length and time scales is fruitful in terms of understanding and describing microstructure evolution of a macroscopic physical process from various perspectives.
ContributorsChen, Shaohua (Author) / Jiao, Yang (Thesis advisor) / Wang, Qinghua (Committee member) / Emady, Heather (Committee member) / Gel, Aytekin (Committee member) / Arizona State University (Publisher)
Created2018
Description
An orthotropic elasto-plastic damage material model (OEPDMM) suitable for impact analysis of composite materials has been developed through a joint research project funded by the Federal Aviation Administration (FAA) and the National Aeronautics and Space Administration (NASA). The developed material model has been implemented into LS-DYNA®, a commercial finite element program. The material model is modular comprising of deformation, damage and failure sub-models. The deformation sub-model captures the rate and/or temperature dependent elastic and inelastic behavior via a visco-elastic-plastic formulation. The damage sub-model predicts the reduction in the elastic stiffness of the material. The failure sub-model predicts when there is no more load carrying capacity in the finite element and erosion of the element from the finite element model. Most of the input parameters required to drive OEPDMM are in the form of tabulated data. The deformation sub-model is driven by a set of tabulated stress-strain data for a given strain-rate and temperature combination. The damage sub-model is driven by tabulated damage parameter-strain data. Two failure sub-models have been implemented – Puck Failure Model and Generalized Tabulated Failure Model. Puck Failure Model requires scalar parameters as input whereas, the Generalized Tabulated Failure Model is driven by a set of equivalent failure strain tabulated data. The work presented here focuses on the enhancements made to OEPDMM with emphasis on the background, development, and implementation of the failure sub-models. OEPDMM is verified and validated using a carbon/epoxy fiber reinforced composite. Two validation tests are used to evaluate the failure sub-model implementation - a stacked-ply test carried out at room temperature under quasi-static tensile and compressive loadings, and several high-speed impact tests where there is significant damage and material failure of the impacted panel. Results indicate that developed procedures provide the analyst with a reasonable and systematic approach to building predictive impact simulation models.
ContributorsLoukham, Shyamsunder (Author) / Rajan, Subramaniam SR (Thesis advisor) / Neithalath, Narayanan NN (Committee member) / Mobasher, Barzin BM (Committee member) / Hoover, Christian CH (Committee member) / Liu, Yongming YL (Committee member) / Arizona State University (Publisher)
Created2020
Description
As the world becomes more electronic, power electronics designers have continuously designed more efficient converters. However, with the rising number of nonlinear loads (i.e. electronics) attached to the grid, power quality concerns, and emerging legislation, converters that intake alternating current (AC) and output direct current (DC) known as rectifiers are increasingly implementing power factor correction (PFC) by controlling the input current. For a properly designed PFC-stage inductor, the major design goals include exceeding minimum inductance, remaining below the saturation flux density, high power density, and high efficiency. In meeting these goals, loss calculation is critical in evaluating designs. This input current from PFC circuitry leads to a DC bias through the filter inductor that makes accurate core loss estimation exceedingly difficult as most modern loss estimation techniques neglect the effects of a DC bias. This thesis explores prior loss estimation and design methods, investigates finite element analysis (FEA) design tools, and builds a magnetics test bed setup to empirically determine a magnetic core’s loss under any electrical excitation. In the end, the magnetics test bed hardware results are compared and future work needed to improve the test bed is outlined.
ContributorsMeyers, Tobin (Author) / Ayyanar, Raja (Thesis advisor) / Qin, Jiangchao (Committee member) / Lei, Qin (Committee member) / Arizona State University (Publisher)
Created2019