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The purpose of this paper is to address the problems of interaction of tensile stress-waves with polyurea/fused-silica and fused-silica/polyurea interfaces, and the potential for the accompanying interfacial decohesion.

The problems are investigated using all-atom non-equilibrium molecular-dynamics methods and tools. Before these methods/tools are employed, previously determined material constitutive relations for polyurea and fused-silica are used, within an acoustic-impedance-matching procedure, to predict the outcome of the interactions of stress-waves with the material-interfaces in question. These predictions pertain solely to the stress-wave/interface interaction aspects resulting in the formation of transmitted and reflected stress- or release-waves, but do not contain any information regarding potential interfacial decohesion. Direct molecular-level simulations confirmed some of these predictions, but also provided direct evidence of the nature and the extent of interfacial decohesion. To properly model the initial state of interfacial cohesion and its degradation during stress-wave-loading, reactive forcefield potentials are utilized.

Direct molecular-level simulations of the polyurea/fused-silica interfacial regions prior to loading revealed local changes in the bonding structure, suggesting the formation of an interphase. This interphase was subsequently found to greatly affect the polyurea/fused-silica decohesion strength.

To the authors’ knowledge, the present work is the first public-domain report of the use of the non-equilibrium molecular dynamics and reactive force-field potentials to study the problem of interfacial decohesion caused by the interaction of tensile waves with material interfaces.

Friction stir welding (FSW) butt-joining involving the use of a dissimilar filler metal insert between the retreating and advancing portions of the workpiece is investigated computationally using a combined Eulerian-Lagrangian (CEL) finite element analysis (FEA). The emphasis of the computational analysis was placed on the understanding of the inter-material mixing and weld-flaw formation during a dissimilar-material FSW process. The paper aims to discuss these issues.

The FEA employed is of a two-way thermo-mechanical character (i.e. frictional-sliding/plastic-work dissipation was taken to act as a heat source in the energy conservation equation), while temperature is allowed to affect mechanical aspects of the model through temperature-dependent material properties. Within the analysis, the workpiece and the filler-metal insert are treated as different materials within the Eulerian subdomain, while the tool was treated as a conventional Lagrangian subdomain. The use of the CEL formulation within the workpiece insert helped avoid numerical difficulties associated with excessive Lagrangian element distortion.

The results obtained revealed that, in order to obtain flaw-free FSW joints with properly mixed filler and base materials, process parameters including the location of the tool relative to the centerline of the weld must be selected judiciously.

To the authors’ knowledge, the present work is the first reported attempt to simulate FSW of dissimilar materials.

The purpose of this paper is to develop multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process has been improved with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties (strength, in particular) within the weld.

The improved GMAW process model is next applied to the case of butt-welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler-metal electrodes made of the same material. A critical assessment is conducted of the basic foundation of the model, including its five modules, each dedicated to handling a specific aspect of the GMAW process, i.e.: first, electro-dynamics of the welding-gun; second, radiation/convection controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; third, prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; fourth, the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and fifth, spatial distribution of the as-welded material mechanical properties.

The predictions of the improved GMAW process model pertaining to the spatial distribution of the material microstructure and properties within the MIL A46100 butt-weld are found to be consistent with general expectations and prior observations.

To explain microstructure/property relationships within different portions of the weld, advanced physical-metallurgy concepts and principles are identified, and their governing equations parameterized and applied within a post-processing data-reduction procedure.

To make wind energy (one of the alternative-energy production technologies) economical, wind-turbines (convertors of wind energy into electrical energy) are required to operate, with only regular maintenance, for at least 20 years. However, some key wind-turbine components (especially the gear-box) often require significant repair or replacement after only three to five years in service. This causes an increase in both the wind-energy cost and the cost of ownership of the wind turbine. The paper aims to discuss these issues.

To overcome this problem, root causes of the gear-box premature failure are currently being investigated using mainly laboratory and field-test experimental approaches. As demonstrated in many industrial sectors (e.g. automotive, aerospace, etc.) advanced computational engineering methods and tools cannot only complement these experimental approaches but also provide additional insight into the problem at hand (and do so with a substantially shorter turn-around time). The present work demonstrates the use of a multi-length-scale computational approach which couples large-scale wind/rotor interactions with a gear-box dynamic response, enabling accurate determination of kinematics and kinetics within the gear-box bearings (the components most often responsible for the gear-box premature failure) and ultimately the structural response (including damage and failure) of the roller-bearing components (e.g. inner raceways).

It has been demonstrated that through the application of this approach, one can predict the expected life of the most failure-prone horizontal axis wind turbine gear-box bearing elements.

To the authors’ knowledge, the present work is the first multi-length-scale study of bearing failure in wind-turbines.

The purpose of this paper is to address the problem of substitution of steel with fiber-reinforced polymer-matrix composite in military-vehicle hull-floors, and identifies and quantifies the associated main benefits and shortcomings.

The problem is investigated using a combined finite-element/discrete-particle computational analysis. Within this analysis, soil (in which a landmine is buried), gaseous detonation products and air are modeled as assemblies of discrete, interacting particles while the hull-floor is treated as a Lagrangian-type continuum structure. Considerable effort has been invested in deriving the discrete-material properties from the available experimental data. Special attention has been given to the derivation of the contact properties since these, in the cases involving discrete particles, contain a majority of the information pertaining to the constitutive response of the associated materials. The potential ramifications associated with the aforementioned material substitution are investigated under a large number of mine-detonation scenarios involving physically realistic ranges of the landmine mass, its depth of burial in the soil, and the soil-surface/floor-plate distances.

The results obtained clearly revealed both the benefits and the shortcomings associated with the examined material substitution, suggesting that they should be properly weighted in each specific case of hull-floor design.

To the authors’ knowledge, the present work is the first public-domain report of the findings concerning the complexity of steel substitution with composite-material in military-vehicle hull-floors.

A simple economic analysis has revealed that in order for wind energy to be a viable alternative, wind-turbines (convertors of wind energy into electrical energy) must be able to operate for at least 20 years, with only regular maintenance. However, wind-turbines built nowadays do not generally possess this level of reliability and durability. Specifically, due to the malfunction and failure of drive-trains/gear-boxes, many wind-turbines require major repairs after only three to five years in service. The paper aims to discuss these issues.

The subject of the present work is the so-called white etch cracking, one of the key processes responsible for the premature failure of gear-box roller-bearings. To address this problem, a multi-physics computational methodology is developed and used to analyze the problem of wind-turbine gear-box roller-bearing premature-failure. The main components of the proposed methodology include the analyses of: first, hydrogen dissolution and the accompanying grain-boundary embrittlement phenomena; second, hydrogen diffusion from the crack-wake into the adjacent unfractured material; third, the inter-granular fracture processes; and fourth, the kinematic and structural response of the bearing under service-loading conditions.

The results obtained clearly revealed the operation of the white-etch cracking phenomenon in wind-turbine gear-box roller-bearings and its dependence on the attendant loading and environmental conditions.

The present work attempts to make a contribution to the resolution of an important problem related to premature-failure and inferior reliability of wind-turbine gearboxes.

The purpose of this paper is to discuss the recently developed multi-physics computational model for the conventional Gas Metal Arc Welding (GMAW) joining process that has been upgraded with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties controlling the ballistic limit (i.e. penetration resistance) of the weld.

The original model consists of five modules, each dedicated to handling a specific aspect of the GMAW process, i.e.: electro-dynamics of the welding-gun; radiation-/convection-controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and spatial distribution of the as-welded material mechanical properties. The model is upgraded through the introduction of the sixth module in the present work in recognition of the fact that in thick steel GMAW weldments, the overall ballistic performance of the armor may become controlled by the (often inferior) ballistic limits of its weld (fusion and heat-affected) zones.

The upgraded GMAW process model is next applied to the case of butt-welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler-metal electrodes made of the same material. The predictions of the upgraded GMAW process model pertaining to the spatial distribution of the material microstructure and ballistic-limit-controlling mechanical properties within the MIL A46100 butt-weld are found to be consistent with general expectations and prior observations.

To the authors’ knowledge, the present work is the first reported attempt to establish, using computational modeling, functional relationships between the GMAW process parameters and the mechanical properties controlling the ballistic limit of the resulting weld.

The design of the Advanced Combat Helmet (ACH) currently in use was optimized by its designers in order to attain maximum protection against ballistic impacts (fragments, shrapnel, etc.) and hard-surface/head collisions. Since traumatic brain injury experienced by a significant fraction of the soldiers returning from the recent conflicts is associated with their exposure to blast, the ACH should be redesigned in order to provide the necessary level of protection against blast loads. The paper aims to discuss this issue.

In the present work, an augmentation of the ACH for improved blast protection is considered. This augmentation includes the use of a polyurea (a nano-segregated elastomeric copolymer) based ACH external coating. To demonstrate the efficacy of this approach, blast experiments are carried out on instrumented head-mannequins (without protection, protected using a standard ACH, and protected using an ACH augmented by a polyurea explosive-resistant coating (ERC)). These experimental efforts are complemented with the appropriate combined Eulerian/Lagrangian transient non-linear dynamics computational fluid/solid interaction finite-element analysis.

The results obtained clearly demonstrated that the use of an ERC on an ACH affects (generally in a beneficial way) head-mannequin dynamic loading and kinematic response as quantified by the intracranial pressure, impulse, acceleration and jolt.

To the authors’ knowledge, the present work is the first reported combined experimental/computational study of the blast-protection efficacy and the mild traumatic brain-injury mitigation potential of polyurea when used as an external coating on a helmet.

The purpose of this paper is computer-aided engineering analysis of the recently proposed side-vent-channel concept for mitigation of the blast-loads resulting from a shallow-buried mine detonated underneath a light tactical vehicle. The concept involves the use of side-vent-channels attached to the V-shaped vehicle underbody, and was motivated by the concepts and principles of operation of the so-called “pulse detonation” rocket engines. By proper shaping of the V-hull and side-vent-channels, venting of supersonically expanding gaseous detonation products is promoted in order to generate a downward thrust on the targeted vehicle.

The utility and the blast-mitigation capacity of this concept were examined in the prior work using computational methods and tools which suffered from some deficiencies related to the proper representation of the mine, soil, and vehicle materials, as well as air/gaseous detonation products. In the present work, an attempt is made to remove some of these deficiencies, and to carry out a bi-objective engineering-optimization analysis of the V-hull and side-vent-channel shape and size for maximum reduction of the momentum transferred to and the maximum acceleration acquired by the targeted vehicle.

Due to the conflicting nature of the two objectives, a set of the Pareto designs was identified, which provide the optimal levels of the trade-off between the two objectives.

To the authors’ knowledge, the present work is the first public-domain report of the side-vent-channel blast-mitigation concept.

The purpose of this paper is to prevent their recession caused through chemical reaction with high-temperature water vapor, SiC-fiber/SiC-matrix ceramic-matrix composite (CMC) components used in gas-turbine engines are commonly protected with so-called environmental barrier coatings (EBCs). EBCs typically consist of three layers: a top thermal and mechanical protection coat; an intermediate layer which provides environmental protection; and a bond coat which assures good EBC/CMC adhesion. The materials used in different layers and their thicknesses are selected in such a way that the coating performance is optimized for the gas-turbine component in question.

Gas-turbine engines, while in service, often tend to ingest various foreign objects of different sizes. Such objects, entrained within the gas flow, can be accelerated to velocities as high as 600 m/s and, on impact, cause substantial damage to the EBC and SiC/SiC CMC substrate, compromising the component integrity and service life. The problem of foreign object damage (FOD) is addressed in the present work computationally using a series of transient non-linear dynamics finite-element analyses. Before such analyses could be conducted, a major effort had to be invested toward developing, parameterizing and validating the constitutive models for all attendant materials.

The computed FOD results are compared with their experimental counterparts in order to validate the numerical methodology employed.

To the authors’ knowledge, the present work is the first reported study dealing with the computational analysis of the FOD sustained by CMCs protected with EBCs.