A Multi-physics Analysis Capability for Engine Materials

Computer-aided Engineering software that apply the Finite Element Method to perform a multi-physics analysis have received widespread acceptance for traditional macro-scale material systems. Challenges persist in the modeling of complex coupled processes in environmental/thermal barrier coatings (E/TBCs) used to protect substrate material against the corrosive environment in the hot section parts of turbine engine. Examples of such processes include a formation of the through-the-thickness cracks, a diffusion of oxygen and moisture through those cracks, and an oxidation and a recession. These detrimental processes in combination with mechanical stresses may eventually lead to a spallation of E/TBCs. E/TBCs advanced material systems can revolutionize the aerospace and related industries by providing means to build fuel-efficient turbine engines operating at elevated temperatures. Analysis of detrimental processes in E/TBCs material systems will be established through a predictive multi- physics (structural, thermal, and environmental) modeling. This modeling will be enabled by hardening of the Peridigm peridynamics code originally developed by Sandia National Laboratories and by an integration of this innovative code with commercial ANSYS software that is the computational tool of choice for aerospace engine applications. Peridigm is a highly efficient, massively-parallel C++ simulation code for solving 3-D problems in structural mechanics and material failure. It is based on the peridynamic method that unifies the mechanics of continuous media, cracks, and discrete particles, thereby potentially avoiding many critical limitations of the traditional Finite Element Method. This Phase I work will harden the Peridigm peridynamics code with a preliminary modeling capability to account for complex, coupled processes in composite material system enhanced with E/TBCs. This will also include a construction of preliminary bridging framework that will integrate the peridynamic code with ANSYS commercial software. Results of feasibility studies for peridynamic-based analysis of material degradation processes in a composite material system protected with E/TBCs against the hot corrosive environment of engine will be documented. The proposed new multi-physics software will be used as a Computer-aided Engineering tool to design E/TBCs material systems capable to withstand the corrosive environment in the hot section parts of turbine engine operating at elevated temperatures. Sunergolab has identified the multi-billion aerospace composite segment as the target market for this new software.