Process modeling and characterization of thermoset composites for residual stress prediction

2021 ◽  
pp. 1-12
Author(s):  
Sagar P. Shah ◽  
Sagar U. Patil ◽  
Christopher J. Hansen ◽  
Gregory M. Odegard ◽  
Marianna Maiarù
Keyword(s):  
Residual Stress ◽  
Process Modeling ◽  
Thermoset Composites ◽  
Stress Prediction

scholarly journals Effect of Manufacturing on the Transverse Response of Polymer Matrix Composites

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2491
Author(s):  
Sagar P. Shah ◽  
Marianna Maiarù
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Process Modeling ◽  
Polymer Matrix Composites ◽  
Effect Study ◽  
Matrix Composites ◽  
Computationally Efficient ◽  
Thermoset Composites ◽  
Residual Stress State ◽  
Composite Stiffness

The effect of residual stress build-up on the transverse properties of thermoset composites is studied through direct and inverse process modeling approaches. Progressive damage analysis is implemented to characterize composite stiffness and strength of cured composites microstructures. A size effect study is proposed to define the appropriate dimensions of Representative Volume Elements (RVEs). A comparison between periodic (PBCs) and flat (FBCs) boundary conditions during curing is performed on converged RVEs to establish computationally efficient methodologies. Transverse properties are analyzed as a function of the fiber packing through the nearest fiber distance statistical descriptor. A reasonable mechanical equivalence is achieved for RVEs consisting of 40 fibers. It has been found that process-induced residual stresses and fiber packing significantly contribute to the scatter in composites transverse strength. Variation of ±5% in average strength and 18% in standard deviation are observed with respect to ideally cured RVEs that neglect residual stresses. It is established that process modeling is needed to optimize the residual stress state and improve composite performance.

scholarly journals Process Modeling of Thermoset Composites used for Wind Blade Manufacturing

2021 ◽  
Author(s):  
Sagar P. Shah ◽  
Sagar U. Patil ◽  
Christopher J. Hansen ◽  
Gregory M. Odegard ◽  
Marianna Maiaru
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Wind Energy ◽  
Process Modeling ◽  
Material Characterization ◽  
Virtual Manufacturing ◽  
Stress Generation ◽  
Cure Cycle ◽  
Thermoset Composites

A computational process modeling framework, informed by accurate material characterization, is presented for virtual manufacturing of wind energy thermoset composites. Process modeling simulations of composite microstructures are carried out to predict in-situ matrix property evolution and performance-altering residual stress generation. To achieve this, comprehensive material characterization effort is carried out. A novel material property dataset for a widely-used wind energy thermoset system is generated as a function of the temperature and curing. Informed by these material properties, the ability of the process model to reliably estimate manufacturing-induced residual stresses is highlighted. For a prescribed cure cycle, in-situ elastic modulus evolution, chemical and thermal strains, and random fiber distribution are shown to significantly influence residual stress generation. The results also show that a full process modeling analysis that includes the complete cure cycle (instead of the standard approach of just considering post-processing cool-down) is necessary to accurately predict manufacturing-induced residual stresses.

Development of a Residual Stress Simulation Benchmark for a Single Bead-on-Plate Weldment

2006 ◽  
Author(s):  
Peter J. Bouchard ◽  
Lyndon Edwards ◽  
Anastasius G. Youtsos ◽  
Roger Dennis
Keyword(s):  
Residual Stress ◽  
Assessment Procedure ◽  
Defect Assessment ◽  
Best Estimate ◽  
Weld Residual Stress ◽  
Single Bead ◽  
Stress Prediction ◽  
Stainless Steel Bead ◽  
Stress Simulation ◽  
Network Project

Finite element weld residual stress modelling procedures involve complex non-linear analyses where many assumptions and approximations have to be made by the analyst. Weld modelling guidelines for inclusion in the R6 defect assessment procedure are in preparation and will be accompanied by a series of validation benchmarks that can be used to evaluate the accuracy of weld modelling procedures and assess their suitability for use in fracture assessments. It is intended to base one of the benchmarks on a stainless steel bead-on-plate weldment that has been extensively studied by members of Task Group 1 of the NeT European Network project. This paper uses round robin residual stress measurements from the NeT project to derive a statistically based ‘best estimate’ distribution of transverse stress passing through the wall-section at mid-length of the bead-on-plate weldment. The accuracy of a state-of-the-art residual stress prediction is benchmarked against the best estimate measurements using a root mean square error analysis and comparisons of decomposed components of stress. The appropriateness of using the predicted residual stresses in fracture assessments is assessed by comparing stress intensity factors based on the measured and predicted distributions of stress. The results from these studies will be used to help establish accuracy targets and acceptance criteria for the welding benchmark.

Polycrystalline Silicon Gettering Layers with Controlled Residual Stress

2013 ◽  
Vol 205-206 ◽  
pp. 284-289 ◽  
Author(s):  
David Lysáček ◽  
Petr Kostelník ◽  
Petr Pánek
Keyword(s):  
Residual Stress ◽  
Vapor Deposition ◽  
Polycrystalline Silicon ◽  
Opposite Sign ◽  
Chemical Vapor ◽  
Pressure Chemical ◽  
Novel Method ◽  
The Individual ◽  
Scanning Electron

We report on a novel method of low pressure chemical vapor deposition of polycrystalline silicon layers used for external gettering in silicon substrate for semiconductor applications. The proposed method allowed us to produce layers of polycrystalline silicon with pre-determined residual stress. The method is based on the deposition of a multilayer system formed by two layers. The first layer is intentionally designed to have tensile stress while the second layer has compressive stress. Opposite sign of the residual stresses of the individual layers enables to pre-determine the residual stress of the gettering stack. We used scanning electron microscopy for structural characterization of the layers and intentional contamination for demonstration of the gettering properties. Residual stress of the layers was calculated from the wafer curvature.

Two Case Studies in 3-D Residual Stress Prediction for Nuclear Power Applications

2016 ◽  
Author(s):  
Michael L. Benson ◽  
Patrick A. C. Raynaud ◽  
Frederick W. Brust
Keyword(s):  
Residual Stress ◽  
Nuclear Power ◽  
Three Dimensional ◽  
Repair Process ◽  
Three Dimensional Modeling ◽  
Dimensional Modeling ◽  
Weld Residual Stress ◽  
Plant Operations ◽  
Stress Prediction ◽  
Residual Stress Modeling

Residual stress prediction contributes to nuclear safety by enabling engineering estimates of component service lifetimes. Subcritical crack growth mechanisms, in particular, require residual stress assumptions in order to accurately model the degradation phenomena. In many cases encountered in nuclear power plant operations, the component geometry permits two-dimensional (i.e., axisymmetric) modeling. Two recent examples, however, required three-dimensional modeling for a complete understanding of the weld residual stress distribution in the component. This paper describes three-dimensional weld residual stress modeling for two cases: (1) branch connection welds off reactor coolant loop piping and (2) a mockup to demonstrate the effectiveness of the excavate and weld repair process.

Characterization of nanocrystalline surface layer induced by shot peening and effect on their fatigue strength.

2004 ◽  
Vol 843 ◽  
Author(s):  
Hideo Mano ◽  
Kondo Satoru ◽  
Akihito Matsumuro ◽  
Toru Imura
Keyword(s):  
Residual Stress ◽  
Surface Layer ◽  
Fatigue Strength ◽  
Vickers Hardness ◽  
Shot Peening ◽  
White Layer ◽  
The Other ◽  
Fatigue Properties ◽  
Nanocrystalline Layer

ABSTRACTThe shot peening process is known to produce a hard layer, known as the white layer” on the surface of coil springs. However, little is known about the fatigue properties of this white-layer.In this study, coil springs with a white-layer were manufactured. The surface of these springs was then examined using micro Vickers hardness, FE-SEM etc. to test fatigue strength of the springs.From the results obtained, a microstructure of the white-layer with grain size of 50–100 nm was observed, with a Vickers hardness rating of 8–10 GPa.Tow category springs were manufactured utilizing a double-peening process. These springs had the same residual stress destruction and surface roughness. Only one difference was observed: one spring had a nanocrystalline layer on the surface, while the other did not. The results of the fatigue test realized an increase in the fatigue life of the nanocrystalline surface layer by 9%.

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