Publications

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The texture of a polycrystalline material refers to the preferred orientation of the grains within the material. In metallic materials, texture can significantly affect the mechanical properties such as elastic moduli, yield stress, strain hardening, and fracture toughness. Recent advances in additive manufacturing of metallic materials offer the possibility in the not too distant future of controlling the spatial variation of texture. In this work, we investigate the advantages, in terms of mechanical performance, of allowing the texture to vary spatially. We use an adjoint-based gradient optimization algorithm within a finite element solver (COMSOL) to optimize several engineering quantities of interest in a simple structure (hole in a plate) and loading (uniaxial tension) condition. As a first step to general texture optimization, we consider the idealized case of a pure fiber texture in which the homogenized properties are transversely isotropic. In this special case, the only spatially varying design variables are the three Euler angles that prescribe the orientation of the homogenized material at each point within the structure. This work paves a new way to design metallic materials for tunable mechanical properties at the microstructure level.

Previous numerical studies of Sylgard filled with glass microballoons (GMB) have relied on various microstructure idealizations to achieve a large range of volume fractions with high mesh quality. This study investigates how different microstructure idealizations and constraints affect the apparent homogenized elastic constants in the virgin state of the material, in which all GMBs are intact and perfectly bonded to the Sylgard matrix, and in the fully damaged state of the material in which all GMBs are destroyed. In the latter state, the material behaves as an elastomeric foam. Four microstructure idealizations are considered relating to how GMBs are packed into a representative volume element (RVE): (1) no boundary penetration nor GMB-GMB overlap, (2) GMB-GMB overlap, (3) boundary penetration, and (4) boundary penetration and GMB-GMB overlap. First order computational homogenization with kinematically uniform displacement boundary conditions (KUBCs) was employed to determine the homogenized (apparent) bulk and shear moduli for the four microstructure idealizations in the intact and fully broken GMB material states. It was found that boundary penetration has a significant effect on the shear modulus for microstructures with intact GMBs, but that neither boundary penetration nor GMB overlap have a significant effect on homogenized properties for microstructures with fully broken GMBs. The primary conclusion of the study is that future investigations into Sylgard/GMB micromechanics should either force GMBs to stay within the RVE fully and/or use periodic BCs (PBCs) to eliminate the boundary penetration issues. The implementation of PBCs requires the improvement of existing tools in Sandia’s Sierra/SM code.

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This work was done to support customer questions about whether a Sylgard/Glass Microballoon (GMB) potting material in current use could be replaced with pure Sylgard and if this would significantly change stresses imparted to internal components under thermal cycling conditions. To address these questions, we provide micromechanics analysis of Sylgard/GMB materials using both analytic composite theory and finite element simulations to better understand the role of the GMB volume fraction in determining thermal expansion coefficient, elastic constants, and behavior in both confined and unconfined compression boundary value problems. A key finding is that damage accumulation in the material from breakage of GMBs significantly limits the global stress magnitude and results in a plateau stress behavior over large ranges of compressive strain. The magnitude of this plateau stress is reduced with higher volume fractions of GMBs. This effect is particularly pronounced in confined compression, which we estimate bears the most similarity to the application of interest. This stress-limiting damage mechanism is not present in pure Sylgard, however, and the result is much higher stresses under confined compression. Thus, we recommend that some volume fraction greater than 10% GMBs be used for confined deformation applications.

We calibrate a linear thermoviscoelastic model for solid Sylgard 184 (90-10 formulation), a lightly cross-linked, highly flexible isotropic elastomer for use both in Sierra / Solid Mechanics via the Universal Polymer Model as well as in Sierra / Structural Dynamics (Salinas) for use as an isotropic viscoelastic material. Material inputs for the calibration in both codes are provided. The frequency domain master curve of oscillatory shear was obtained from a report from Los Alamos National Laboratory (LANL). However, because the form of that data is different from the constitutive models in Sierra, we also present the mapping of the LANL data onto Sandia’s constitutive models. Finally, blind predictions of cyclic tension and compression out to moderate strains of 40 and 20% respectively are compared with Sandia’s legacy cure schedule material. Although the strain rate of the data is unknown, the linear thermoviscoelastic model accurately predicts the experiments out to moderate strains for the slower strain rates, which is consistent with the expectation that quasistatic test procedures were likely followed. This good agreement comes despite the different cure schedules between the Sandia and LANL data.

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An a posteriori error-estimation framework is introduced to quantify and reduce modeling errors resulting from approximating complex mesoscale material behavior with a simpler macroscale model. Such errors may be prevalent when modeling welds and additively manufactured structures, where spatial variations and material textures may be present in the microstructure. We consider a case where a <100> fiber texture develops in the longitudinal scanning direction of a weld. Transversely isotropic elastic properties are obtained through homogenization of a microstructural model with this texture and are considered the reference weld properties within the error-estimation framework. Conversely, isotropic elastic properties are considered approximate weld properties since they contain no representation of texture. Errors introduced by using isotropic material properties to represent a weld are assessed through a quantified error bound in the elastic regime. Lastly, an adaptive error reduction scheme is used to determine the optimal spatial variation of the isotropic weld properties to reduce the error bound.

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An a posteriori error-estimation framework is introduced to quantify and reduce modeling errors resulting from approximating complex mesoscale material behavior with a simpler macroscale model. Such errors may be prevalent when modeling welds and additively manufactured structures, where spatial variations and material textures may be present in the microstructure. We consider a case where a <100> fiber texture develops in the longitudinal scanning direction of a weld. Transversely isotropic elastic properties are obtained through homogenization of a microstructural model with this texture and are considered the reference weld properties within the error-estimation framework. Conversely, isotropic elastic properties are considered approximate weld properties since they contain no representation of texture. Errors introduced by using isotropic material properties to represent a weld are assessed through a quantified error bound in the elastic regime. An adaptive error reduction scheme is used to determine the optimal spatial variation of the isotropic weld properties to reduce the error bound.

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