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Papers by Md Abir Hossain

Research paper thumbnail of An Accelerated Creep Testing (ACT) Program for Advanced Creep Resistant Alloys for High Temperature Fossil Energy (FE) Applications (Final Report)

Accelerated creep testing (ACT) is a well-established method to reduce the time-for-material-qual... more Accelerated creep testing (ACT) is a well-established method to reduce the time-for-material-qualification; however, none of the existing ACTs provide rapid and detailed information concerning long term creep deformation and rupture behavior. Of primary concern to the FE materials scientist is the rapid experimental screening of the long-term creep behavior of candidate materials. 3 The Research Objective (RO) of this project is to vet, improve, and test the feasibility of the Stepped Isostress Method and Stress Relaxation Test for metallic materials.

Research paper thumbnail of Probabilistic Creep Modeling of 304 Stainless Steel Using Modified Wilshire Creep-Damage Model

Research paper thumbnail of Calibration of CDM-Based Creep Constitutive Model Using Accelerated Creep Test (ACT) Data

Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Marine; Microturbines, Turbochargers, and Small Turbomachines, 2020

In conventional creep testing (CCT) a specimen is subject to constant load and temperature for a ... more In conventional creep testing (CCT) a specimen is subject to constant load and temperature for a long-duration until creep rupture occurs. Conventional testing can be costly when considering the number of experiments needed to characterize the creep response of a material over a range of stress and temperature. To predict long-term creep-rupture properties, the time-temperature-stress superposition principle (TTSSP) approach has been employed where stress and/or temperature is applied at an elevated level; the result of which are extrapolated down to low stress and/or temperature conditions. These methods have been successful in predicting minimum-creep-strain-rate (MCSR) and stress-rupture (SR) but suffer from an inability to predict the creep deformation curve or account for changes in deformation mechanisms or aging that occurs at long-duration. An accelerated technique, termed the Stepped isostress method (SSM) allows the accelerated testing of materials to determine their creep...

Research paper thumbnail of Reliability Prediction of 304 Stainless Steel Using Sine-Hyperbolic Creep-Damage Model With Monte Carlo Simulation Method

Volume 6A: Materials and Fabrication, 2019

Typically continuum damage mechanics (CDM) based constitutive models are applied deterministicall... more Typically continuum damage mechanics (CDM) based constitutive models are applied deterministically where the uncertainty of experiments is not considered. This is also true for the Sine-hyperbolic (Sinh) CDM-based constitutive model where the model is calibrated to represent 50% reliability of creep data. There is a need to implement Sinh in a more stochastic manner. The objectives of this study is to incorporate the probabilistic feature in the Sinh creep damage model to reliably predict the minimum-creep-strain-rate, creep-rupture and creep deformation. This will be achieved using Monte-Carlo methods. Creep deformation data for 304 Stainless Steel is collected from literature consisting of tests conducted at 300 and 320 MPa at 600°C with five replicates. The replicate tests exhibited substantial scatter in the minimum-creep-strain-rate, stress-rupture, and overall creep deformation. Subsequently, upon calibration using the Sinh model, the material constants among the replicates va...

Research paper thumbnail of Accelerated Creep Testing of Inconel 718 Using the Stepped Isostress Method (SSM)

Materials Performance and Characterization, 2021

This paper demonstrates the stepped isostress method (SSM), an accelerated creep test (ACT) for t... more This paper demonstrates the stepped isostress method (SSM), an accelerated creep test (ACT) for the rapid assessment of metallic materials. The SSM test is based on the time-temperature-stress superposition principle in which temperature, stress, or both, are step increased to accelerate the time to rupture. The SSM test has proven successful for the ACT of polymers and polymeric composites but has yet to be proven for metallic materials. In this study, new test matrix design rules for the SSM of metals are established based on deformation mechanism, time-temperature transformation, and time-temperature precipitation maps. A test matrix of SSM and conventional creep tests (CCTs) are executed for alloy Inconel 718 at 750°C (1,382°F) with stress levels ranging from 100 to 350 MPa. Validation CCT data are gathered from the Japan National Institute of Material Science. Material constants for the Sine-hyperbolic (Sinh) constitutive model are calibrated using the SSM data and employed to predict the conventional creep response. When blindly compared with the CCT data, the SSM-calibrated Sinh model can accurately predict the conventional creep response across logarithmic decades and, thus, accelerate the capture of conventional creep data. Fractography indicates ductile fracture by transgranular microvoid coalescence with the same fracture mode observed in both SSM and CCT specimens. Creep cavitation is indicated by the population, smoothness, and size of microvoids.

Research paper thumbnail of Probabilistic Minimum-Creep-Strain-Rate and Stress-Rupture Prediction for the Long-Term Assessment of IGT Components

Volume 10B: Structures and Dynamics, 2020

Time-dependent creep induced failure is a major concern for structural components (i.e. IGT compo... more Time-dependent creep induced failure is a major concern for structural components (i.e. IGT components, Gen IV nuclear reactor components) operating at elevated temperature. The likelihood of a failure is aggravated by randomness in several sources of uncertainty. Creep rupture data shows expanding scatter bands for long-duration creep tests where uncertainty can span multiple logarithmic decades of life. This experimental uncertainty is exacerbated by the uncertainties that exist during service. The continuum damage mechanics (CDM) based creep-damage model readily available in literature does not consider the uncertainty effect while predicting the long-term reliability of the components; rather the problem is tackled deterministically. Introduction of probabilistic phenomena into the existing model to predict the minimum-creep-strain-rate (MCSR) and stress-rupture (SR) would present a pathway for estimation of effect of uncertainty ensuing high reliability in the assessment. The o...

Research paper thumbnail of A probabilistic creep model incorporating test condition, initial damage, and material property uncertainty

International Journal of Pressure Vessels and Piping, 2021

Abstract Uncertainty is prevalent in the creep resistance of alloys, where at elevated temperatur... more Abstract Uncertainty is prevalent in the creep resistance of alloys, where at elevated temperature and low pressure, rupture can range across logarithmic decades. In this study, a probabilistic continuum-damage-mechanics (CDM)-based model is derived to capture the uncertainty of creep resistance. To meet this objective, creep data for alloy 304 Stainless Steel is gathered. A constitutive model, “Sinh”, is calibrated deterministically to determine the statistical variability of the material properties. Three sources of uncertainty are injected into the model: test condition (stress and temperature), initial damage, and material properties. Probabilistic simulations are carried out by (a) calibrating probability distribution functions (pdfs) for each source of uncertainty (b) randomly sampling the pdfs using Monte Carlo methods and (c) executing simulations to replicate the uncertain creep behavior. A sensitivity analysis is performed to evaluate the relative effect of each source of uncertainty. In full probabilistic simulations, the cumulative uncertainty of creep behavior is evaluated. The probabilistic model accurately predicts the creep deformation and rupture of the available experiments. The probabilistic model is validated for interpolation but lacks extrapolation ability. Several future works are proposed to further improve the model.

Research paper thumbnail of A Reduced Order Modeling Approach to Probabilistic Creep-Damage Predictions in Finite Element Analysis

Volume 9B: Structures and Dynamics — Fatigue, Fracture, and Life Prediction; Probabilistic Methods; Rotordynamics; Structural Mechanics and Vibration, 2021

This paper introduces a computationally efficient Reduced Order Modeling (ROM) approach for the p... more This paper introduces a computationally efficient Reduced Order Modeling (ROM) approach for the probabilistic prediction of creep-damage failure. Component-level probabilistic simulations are needed to assess the reliability and safety of high-temperature components. Full-scale probabilistic creep-damage modeling in finite element (FE) approach is computationally expensive requiring many hundreds of simulations to replicate the uncertainty of component failure. To that end, ROM is proposed to minimize the elevated computational cost while controlling the loss of accuracy. It is proposed that full-scale probabilistic simulations can be completed in 1D at a reduced cost, the extremum conditions extracted, and those conditions applied for lower cost 2D/3D probabilistic simulations of components that capture the mean and uncertainty of failure. The probabilistic Sine-hyperbolic (Sinh) model is selected which in previous work was calibrated to alloy 304 stainless steel. The Sinh model in...

Research paper thumbnail of An Extrema Approach to Probabilistic Creep Modeling in Finite Element Analysis

Journal of Engineering for Gas Turbines and Power, 2021

This paper introduces a computationally efficient extrema approach for the probabilistic predicti... more This paper introduces a computationally efficient extrema approach for the probabilistic predictions of creep in finite element analysis (FEA). Component-level probabilistic simulations are needed to assess the reliability and safety of high-temperature components. Full-scale probabilistic creep models in FEA are computationally expensive, requiring many hundreds of simulations to replicate the uncertainty of component failure. Extrema are conditions at which the values of a function are the largest or the smallest. In this study, an extrema approach is proposed. In the extrema approach, full-scale probabilistic simulations are completed in one-dimensional across a wide range of stresses, the results are processed, and extrema conditions are extracted. The extrema conditions alone are applied in two-/three-dimensional FEA to predict the mean and range of creep failure. The probabilistic Sinh model, calibrated for alloy 304 stainless steel, is selected. The sources of uncertainty (i....

Research paper thumbnail of An Accelerated Creep Testing (ACT) Program for Advanced Creep Resistant Alloys for High Temperature Fossil Energy (FE) Applications (Final Report)

Accelerated creep testing (ACT) is a well-established method to reduce the time-for-material-qual... more Accelerated creep testing (ACT) is a well-established method to reduce the time-for-material-qualification; however, none of the existing ACTs provide rapid and detailed information concerning long term creep deformation and rupture behavior. Of primary concern to the FE materials scientist is the rapid experimental screening of the long-term creep behavior of candidate materials. 3 The Research Objective (RO) of this project is to vet, improve, and test the feasibility of the Stepped Isostress Method and Stress Relaxation Test for metallic materials.

Research paper thumbnail of Probabilistic Creep Modeling of 304 Stainless Steel Using Modified Wilshire Creep-Damage Model

Research paper thumbnail of Calibration of CDM-Based Creep Constitutive Model Using Accelerated Creep Test (ACT) Data

Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Marine; Microturbines, Turbochargers, and Small Turbomachines, 2020

In conventional creep testing (CCT) a specimen is subject to constant load and temperature for a ... more In conventional creep testing (CCT) a specimen is subject to constant load and temperature for a long-duration until creep rupture occurs. Conventional testing can be costly when considering the number of experiments needed to characterize the creep response of a material over a range of stress and temperature. To predict long-term creep-rupture properties, the time-temperature-stress superposition principle (TTSSP) approach has been employed where stress and/or temperature is applied at an elevated level; the result of which are extrapolated down to low stress and/or temperature conditions. These methods have been successful in predicting minimum-creep-strain-rate (MCSR) and stress-rupture (SR) but suffer from an inability to predict the creep deformation curve or account for changes in deformation mechanisms or aging that occurs at long-duration. An accelerated technique, termed the Stepped isostress method (SSM) allows the accelerated testing of materials to determine their creep...

Research paper thumbnail of Reliability Prediction of 304 Stainless Steel Using Sine-Hyperbolic Creep-Damage Model With Monte Carlo Simulation Method

Volume 6A: Materials and Fabrication, 2019

Typically continuum damage mechanics (CDM) based constitutive models are applied deterministicall... more Typically continuum damage mechanics (CDM) based constitutive models are applied deterministically where the uncertainty of experiments is not considered. This is also true for the Sine-hyperbolic (Sinh) CDM-based constitutive model where the model is calibrated to represent 50% reliability of creep data. There is a need to implement Sinh in a more stochastic manner. The objectives of this study is to incorporate the probabilistic feature in the Sinh creep damage model to reliably predict the minimum-creep-strain-rate, creep-rupture and creep deformation. This will be achieved using Monte-Carlo methods. Creep deformation data for 304 Stainless Steel is collected from literature consisting of tests conducted at 300 and 320 MPa at 600°C with five replicates. The replicate tests exhibited substantial scatter in the minimum-creep-strain-rate, stress-rupture, and overall creep deformation. Subsequently, upon calibration using the Sinh model, the material constants among the replicates va...

Research paper thumbnail of Accelerated Creep Testing of Inconel 718 Using the Stepped Isostress Method (SSM)

Materials Performance and Characterization, 2021

This paper demonstrates the stepped isostress method (SSM), an accelerated creep test (ACT) for t... more This paper demonstrates the stepped isostress method (SSM), an accelerated creep test (ACT) for the rapid assessment of metallic materials. The SSM test is based on the time-temperature-stress superposition principle in which temperature, stress, or both, are step increased to accelerate the time to rupture. The SSM test has proven successful for the ACT of polymers and polymeric composites but has yet to be proven for metallic materials. In this study, new test matrix design rules for the SSM of metals are established based on deformation mechanism, time-temperature transformation, and time-temperature precipitation maps. A test matrix of SSM and conventional creep tests (CCTs) are executed for alloy Inconel 718 at 750°C (1,382°F) with stress levels ranging from 100 to 350 MPa. Validation CCT data are gathered from the Japan National Institute of Material Science. Material constants for the Sine-hyperbolic (Sinh) constitutive model are calibrated using the SSM data and employed to predict the conventional creep response. When blindly compared with the CCT data, the SSM-calibrated Sinh model can accurately predict the conventional creep response across logarithmic decades and, thus, accelerate the capture of conventional creep data. Fractography indicates ductile fracture by transgranular microvoid coalescence with the same fracture mode observed in both SSM and CCT specimens. Creep cavitation is indicated by the population, smoothness, and size of microvoids.

Research paper thumbnail of Probabilistic Minimum-Creep-Strain-Rate and Stress-Rupture Prediction for the Long-Term Assessment of IGT Components

Volume 10B: Structures and Dynamics, 2020

Time-dependent creep induced failure is a major concern for structural components (i.e. IGT compo... more Time-dependent creep induced failure is a major concern for structural components (i.e. IGT components, Gen IV nuclear reactor components) operating at elevated temperature. The likelihood of a failure is aggravated by randomness in several sources of uncertainty. Creep rupture data shows expanding scatter bands for long-duration creep tests where uncertainty can span multiple logarithmic decades of life. This experimental uncertainty is exacerbated by the uncertainties that exist during service. The continuum damage mechanics (CDM) based creep-damage model readily available in literature does not consider the uncertainty effect while predicting the long-term reliability of the components; rather the problem is tackled deterministically. Introduction of probabilistic phenomena into the existing model to predict the minimum-creep-strain-rate (MCSR) and stress-rupture (SR) would present a pathway for estimation of effect of uncertainty ensuing high reliability in the assessment. The o...

Research paper thumbnail of A probabilistic creep model incorporating test condition, initial damage, and material property uncertainty

International Journal of Pressure Vessels and Piping, 2021

Abstract Uncertainty is prevalent in the creep resistance of alloys, where at elevated temperatur... more Abstract Uncertainty is prevalent in the creep resistance of alloys, where at elevated temperature and low pressure, rupture can range across logarithmic decades. In this study, a probabilistic continuum-damage-mechanics (CDM)-based model is derived to capture the uncertainty of creep resistance. To meet this objective, creep data for alloy 304 Stainless Steel is gathered. A constitutive model, “Sinh”, is calibrated deterministically to determine the statistical variability of the material properties. Three sources of uncertainty are injected into the model: test condition (stress and temperature), initial damage, and material properties. Probabilistic simulations are carried out by (a) calibrating probability distribution functions (pdfs) for each source of uncertainty (b) randomly sampling the pdfs using Monte Carlo methods and (c) executing simulations to replicate the uncertain creep behavior. A sensitivity analysis is performed to evaluate the relative effect of each source of uncertainty. In full probabilistic simulations, the cumulative uncertainty of creep behavior is evaluated. The probabilistic model accurately predicts the creep deformation and rupture of the available experiments. The probabilistic model is validated for interpolation but lacks extrapolation ability. Several future works are proposed to further improve the model.

Research paper thumbnail of A Reduced Order Modeling Approach to Probabilistic Creep-Damage Predictions in Finite Element Analysis

Volume 9B: Structures and Dynamics — Fatigue, Fracture, and Life Prediction; Probabilistic Methods; Rotordynamics; Structural Mechanics and Vibration, 2021

This paper introduces a computationally efficient Reduced Order Modeling (ROM) approach for the p... more This paper introduces a computationally efficient Reduced Order Modeling (ROM) approach for the probabilistic prediction of creep-damage failure. Component-level probabilistic simulations are needed to assess the reliability and safety of high-temperature components. Full-scale probabilistic creep-damage modeling in finite element (FE) approach is computationally expensive requiring many hundreds of simulations to replicate the uncertainty of component failure. To that end, ROM is proposed to minimize the elevated computational cost while controlling the loss of accuracy. It is proposed that full-scale probabilistic simulations can be completed in 1D at a reduced cost, the extremum conditions extracted, and those conditions applied for lower cost 2D/3D probabilistic simulations of components that capture the mean and uncertainty of failure. The probabilistic Sine-hyperbolic (Sinh) model is selected which in previous work was calibrated to alloy 304 stainless steel. The Sinh model in...

Research paper thumbnail of An Extrema Approach to Probabilistic Creep Modeling in Finite Element Analysis

Journal of Engineering for Gas Turbines and Power, 2021

This paper introduces a computationally efficient extrema approach for the probabilistic predicti... more This paper introduces a computationally efficient extrema approach for the probabilistic predictions of creep in finite element analysis (FEA). Component-level probabilistic simulations are needed to assess the reliability and safety of high-temperature components. Full-scale probabilistic creep models in FEA are computationally expensive, requiring many hundreds of simulations to replicate the uncertainty of component failure. Extrema are conditions at which the values of a function are the largest or the smallest. In this study, an extrema approach is proposed. In the extrema approach, full-scale probabilistic simulations are completed in one-dimensional across a wide range of stresses, the results are processed, and extrema conditions are extracted. The extrema conditions alone are applied in two-/three-dimensional FEA to predict the mean and range of creep failure. The probabilistic Sinh model, calibrated for alloy 304 stainless steel, is selected. The sources of uncertainty (i....