SEARCH · Search NASA
Results for “Ductile fracture”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Behavior and properties of helium cavities in ductile-phase-toughened tungsten irradiated with He + ions at an elevated temperature
Ductile-phase toughened tungsten (DPT W) composites have demonstrated a great potential for plasma-facing components in fusion power systems. These materials can retain the outstanding thermomechanical properties of W while significantly enhancing the fracture toughness. The DPT W composite in this study consists of W particles (88 wt.%) embedded in a ductile NiFeW (12 wt.%) solution matrix. Irradiation of the composite was performed with 90 keV He + ions to 1.0 × 10 17 He + /cm 2 at 973 K. The He cavities formed in both W and NiFeW phases are examined using convergent-beam scanning transmission electron microscopy (CB-STEM) at an atomic-level resolution. Full-range depth profiles of the He cavity diameters and number densities are analyzed. The results show that the average cavity diameter in NiFeW is ~2.7 times that in W, while the number density is an order of magnitude lower. A quantitative analysis of the He density and pressure in the cavities is also achieved using STEM electron energy loss spectroscopy (STEM-EELS) mapping. The He atoms in the cavities in NiFeW are found to be under-pressurized, while those in similar-sized cavities in W are not detectable. Further, the He energy-loss shift exhibits a linear relationship with the He density in cavities in NiFeW, with the slope comparable to that for martensitic steel.
Multilayer Architecture Barriers for High Temperature Nuclear Applications
Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.
Interfacial microstructure and mechanical properties of rotary inertia friction welded dissimilar 422 martensitic stainless steel to 4140 low alloy steel joints
In this work, dissimilar rotary inertia friction welds between 422 martensitic stainless steel and 4140 martensitic low-alloy steel were made to fabricate prototype heavy-duty diesel engine pistons. The influence of the inertia friction welding process and post weld heat treatment (PWHT) temperature on the interfacial microstructure evolutions and corresponding effects on mechanical properties of the 422/4140 welds were evaluated in detail. Carbon diffused from the 4140 side to the 422 side during PWHT at 650 °C for 1.5 h, causing the formation of a hard carbide-rich layer on the 422 side, and a softer but discontinuous C-depleted layer the 4140 side. PWHT at 700 °C for 1.5 h greatly accelerated C diffusion across the interface relative to 650 °C, resulting in a thicker hard carbide-rich layer and a relatively thick and continuous layer of coarse C-depleted grains (ferrite) on the 4140 side. In addition, the PWHT temperature greatly influenced the tensile properties and fracture behavior of the welds, with the 650 °C PWHT-ed samples failing predominately in a ductile manner in the 4140 heat affected zone during tensile testing. Conversely, the 700 °C PWHT specimens exhibited a strength reduction compared with the 650 °C PWHT specimens because of additional coarsening of the interfacial ferrite layer and softening of the base materials during PWHT, with brittle fracture between the hard and soft layers the predominate failure mechanism. Based on the findings, a reduced PWHT temperature and/or time, minimizing the hardness differential of the base metals, and pre-heating the 422 steel prior to welding are the potential pathways to achieve a more optimal balance between desirable tempering and stress relief of the weld microstructure and undesirable C migration across the weld interface, and to reduce the strength mismatch across the weld.
Understanding the Elastic, Plastic, and Damage Features in Fracturing of Self-reinforced Thermoplastic Composites via Non-destructive Digital Imaging Correlation
This work demonstrated the utilization of non-destructive Digital Imaging Correlation (DIC) method to characterize the elastic, plastic, and damage features during the Mode I intra-laminar fracturing process of self-reinforced thermoplastic composites by using a self-reinforced polypropylene (PP) composite as an example. The DIC results clearly showed the development of huge plastic zone (PZ) and non-negligible Fracture Process Zone (FPZ) in front of the notch tip during the fracturing process, and the geometries and sizes of the foregoing zones at the peak load were further quantified. Such an interesting fracturing behavior of self-reinforced thermoplastic composites is way different from brittle materials (e.g., glass, acrylic, etc.), ductile materials (e.g., aluminum, steel, etc.), and even quasi-brittle materials (e.g., concrete, nanoparticle-reinforced composites, tough ceramics, wood, cement, carbon/glass fiber-reinforced polymers, etc.). Thus, understanding the elastic, plastic, and damage features is the first step before better characterizing the material fracture properties of self-reinforced thermoplastic composites through new analytical methods and computational modeling. These efforts are of utmost importance for wide applications of self-reinforced thermoplastic composites in various engineering fields in the future.
Finite deformation implementation of a mixed-mode single-integral type cohesive zone with reorienting surfaces of separation
To model material ductile failure and crack propagation, cohesive zone elements can be embedded along potential fracture paths in a finite element simulation. When damage criteria are met, elements in the mesh decohere, simulating the formation and propagation of a crack. In this paper, we present a novel computational algorithm based on finite deformation theory, essential to modeling crack initiation and growth in solids undergoing large deformations. This new algorithm was formulated within a Lagrangian frame of reference to extend previous cohesive zone algorithms to include modeling crack growth in finite deformation contexts. The local coordinate system, necessary for defining an embedded cohesive zone, is constructed based upon the current configuration and is updated within the nonlinear iteration process, thereby resulting in the convergence of the solution for a growing crack in a large deformation quasi-static setting. The model’s accuracy was demonstrated by comparing finite element model simulation results with the analytic case of a constant surface separation, as shown in the verification examples. The power and efficacy of the algorithm to capture large deformations during crack growth were then demonstrated with a double cantilever beam example case. It indicates that the model can be applied to a variety of physical circumstances for predicting crack initiation and growth with delamination and fracture.
Effect of Specimen Thickness on Fracture Toughness and Plane Stress to Plane Strain Transition in Medium-Density Polyethylene
This study investigates the effect of specimen thickness on fracture toughness and the transition from plane stress to plane strain conditions in Medium-Density Polyethylene (MDPE) using Single Edge Notched Bend (SENB) specimens. Three thickness groups (7.5 mm, 9.0 mm, and 12.1 mm) were tested following ASTM D5045 protocol. Conditional stress intensity factors (KQ) increased from 2.2 MPavm to 2.8 MPavm with increasing thickness, demonstrating significant size dependency. Confocal microscopy revealed a 34% reduction in maximum crack tip opening displacement (CTOD) from 0.478 mm to 0.314 mm as thickness increased, with plastic zone lateral extent decreasing by 32%. This quantitative evidence validates Irwin's theoretical prediction of plastic zone size transition from plane stress r_y˜ (1/2p) (K_I/s_y )^2 to plane strain conditions r_y˜ (1/6p) (K_I/s_y )^2.Scanning electron microscopy confirmed progressive suppression of shear lips and evolution from ductile tearing with extensive polymer chain drawing in thin specimens to localized crazing in thick specimens. Despite all specimens satisfying the ASTM D5045 criterion (B = 2.5(KQ/s_y )^2 ) ,residual shear lips persisted even in the thickest specimens, demonstrating that nominal size requirements alone are insufficient for achieving complete plane strain conditions in highly ductile polymers. The findings emphasize the necessity of integrated analytical and morphological assessment for valid fracture toughness characterization, with critical implications for life assessment and integrity prediction in thick-section polymer components such as natural gas distribution pipelines.
Effect of strain rate on the deformation of hollow CoS nanoboxes and doubly porous self-assembled films
Nanomaterials with multiscale porosity are attractive as lightweight structural materials because unique deformation mechanisms can be programmed at different length scales. Here, we explore this concept by investigating the mechanics of hollow nanoboxes, as well as films self-assembled from nanoboxes. Hollow CoS nanoboxes with lengths of 900 nm and <30 nm wall thickness are synthesized using colloidal methods. Individual nanoboxes are compressed inside a scanning electron microscope at strain rates of 0.001 s –1 , 0.01 s –1 , and 0.1 s –1 . Nanoboxes are found to have a first peak stress of 15 MPa and loading modulus of ~240 MPa regardless of strain rate. The nanoboxes deform through ductile, plastic bending of side walls at 0.001 s –1 strain rate, while brittle fracture occurs at the higher strain rates. Self-assembly of these nanoboxes results in films with relative density of <0.1. Nanoindentation shows strain rate independent behavior with average modulus and hardness of ~15 MPa and ~230 kPa, respectively. Furthermore, the mechanical behavior of the film is compared to that of the nanobox building blocks, cellular foams and granular materials.
Experiments and Modeling of Proppant Embedment and Fracture Conductivity for the Caney Shale, Oklahoma, USA
ABSTRACT: The ultimate aim of hydraulic fracturing is to have a long and conductive flow path that extends from the wellbore into the formation. The effective fracture length is part of a hydraulically propped fracture which contributes to production. The difficulty in achieving economical production targets from shale reservoirs is at the forefront in many exploration companies. Fracture conductivity loss is related to; proppant embedment under depletion, proppant crushing, damage as a result of fracturing fluid, fines migration and proppant-pack permeability-damage are some of the factors that contribute to production decline after hydraulic fracturing in shale reservoirs. The Caney Shale is a calcareous organic-rich mudrock. Various studies have investigated the effect that clay on shale well productivity, however, there is currently no literature on the Caney shale in relation to horizontal wells; all available literature exists in vertical wells as well as on formations of the Caney that are shallow in comparison to an emerging play which is twice the depth. In this paper we investigate stress-dependent fracture conductivity of proppant-filled fractures and proppant embedment in Caney shale through laboratory and modeling studies. API fracture conductivity tests were conducted using 2% KCl on five locations within the Caney shale that consisted of selecting three brittle(reservoir) zones and two ductile zones. Confining pressures range from 1,000 psi to 12,000 psi at 210°F. Conductivity, permeability as well as embedment were measured during the test. Our experimental results have confirmed that improved fracture conductivity is attributed to; proppant size, the increase in porosity of the proppant pack, closure pressure changes and the reduction in fracture conductivity are a function of many factors such as fracture closure stress. The findings from this study could help the stimulation design by providing new insights into the critical factors that are to be determined to facilitate the choice of proppants as well as fracturing fluids for long term production and recovery from shale reservoirs. 1 INTRODUCTION The development of low permeability formations, like shales, has been aided by hydraulic fracturing of horizontal wells (Radonjic et al., 2020). Hydraulic fracturing fluid is injected at a high pressure to induce tensile fractures that can link to and stimulate natural fractures (Katende et al., 2021a,b). Preserving adequate conductivity in hydraulic fractures over the life of the wells is required for economic production; nevertheless, conserving such conductivity can be difficult in some circumstances, particularly in soft, clay-rich formations (Wang et al., 2021). Proppant particles help to keep the fractures open when the pumping stops and the fracturing fluid returns to the wellbore, producing one or more propped hydraulic fractures of varying length, breadth, and height (Katende et al., 2021a). The proppant pack within the hydraulic fracture boosts well output by providing a greater permeability flowpath for hydrocarbons (Duenckel et al., 2016). Proppant in the fracture is under complicated stress conditions, and the interplay between the rock formation and the proppant pack has a significant impact on proppant-pack permeability (Karazincir et al., 2019). Proppant may be embedded (Katende et al., 2021a) in the rock or crushed into small pieces if the proppant size and strength characteristics are not specified appropriately, resulting in a loss in proppant-pack permeability and fracture aperture, and consequently a fall in well output.
Deformation and Fracture Behavior of Additively Manufactured 316L Stainless Steel
Tensile deformation and fracture behavior of an additively manufactured (AM) 316L stainless steel (SS) in the as-built, stress-relieved, and solution-annealed conditions was investigated using in situ tensile testing in a scanning electron microscope with an electron back scattering diffraction (SEM–EBSD) detector. Analyses were performed to discuss the characteristic deformation and fracture process of the fine-grained AM 316L SS with and without relaxation heat treatment. The as-built 316L showed the highest strength, and both post-build heat treatments lowered the strength of the alloy. Regardless of the post-build processing, the AM 316L SS showed overall higher strength but slightly lower ductility when compared to the wrought (WT) 316L SS. Analysis of EBSD data indicated that the characteristic microstructural features from AM, such as the complex and fine grain morphology, dislocation network, pores, and silicon-rich oxides, evolved and exerted various roles during the tensile deformation and fracture processes. Further, it was obvious that the interaction of dislocation slips with oxide particles and cavities (or pores) resulted in an accelerated cracking in AM 316L SS. Overall, however, their influence on mechanical behavior was limited, as the genuinely high ductility of 316L SS could help avoid any premature or brittle fracture.
A General Model for the Ductility of Intermetallics Applied to Fe-Co Alloys
The mechanical properties, specifically ductility, of high performing soft magnets such as Fe-Co alloys are a limiting factor to their broader use in a number of systems. The understanding of the mechanical robustness in these materials is currently insufficient to be able to support the growing interest in applications such as magnetic shielding or electric motors. Fe-Co alloys provide the highest commercially available magnetic saturation and high magnetic permeability but have very poor ductility. The addition of vanadium to these alloys has allowed for significant commercialization and some ductility improvements, but the fundamental reasons for the observed improvements are not well understood. In most published work on mechanical properties in these alloys, the precise chemistry of the alloys investigated, often a critical aspect of intermetallics, is not reported or controlled and thermal history is unclear. This work creates a ductility model that is sensitive to changes in chemistry and can predict relative strain to failure as well as brittle fracture mode for intermetallics and is applied to Fe-Co alloys. Through the application of density functional theory (DFT), this model identifies defect stabilities, anti-phase boundary (APB) energies, the energy necessary to cross-slip, and cleavage energies and combines them through energetic competition to determine a relative failure strain. The model correctly predicts ductility improvements with the addition of vanadium as well as the transition from intergranular to transgranular cleavage, though more precise experiments are necessary to appropriately validate the various improvements observed.
A boundary-based approach to the multiscale microstructural characterization of a W-Ni-Fe tungsten heavy alloy
Here, a combination electron backscattered diffraction and transmission electron microscopy based approach has been implemented to study the effects of purposefully introduced anisotropy in a tungsten heavy alloy (WHA) through hot-rolling. Particular attention has been paid to changes in number and proportion of various boundary types from a quantitative standpoint; incorporating qualitative behavioral observations from prior analyses to generate experimentally-validated bases for the examination and application of a microstructure which exhibits an optimal balance of strength and ductility. It is asserted that a combination of increased temperatures during rolling and additional isothermal hold time for the post-rolling annealing steps may lead to a reduction in unfavorable textural components due to rolling in the W-phase and a decrease in premature fracture due to W-W microcracking respectively. This is expected to further increase the proportion of interphase boundaries and improve the ductility of these rolled structures, producing a superior rolled WHA microstructure.
On the bulk compaction of brittle granular materials, Part III: Brittle‐to‐ductile transition and yield strength
A new and simple method is presented that enables the estimation of the yield strength (σ y ) of brittle materials (e.g., ceramics, glasses). It results from the combination of sufficiently high-stress compaction of their granular form, postmortem analysis of the crushed particles to identify the critical particle size corresponding to their brittle-to-ductile transition, and the use of a developed and simple analytical expression. Here, this method was an outcome from Part I of this three-paper series. To execute it, a granular brittle material is compacted to a sufficiently high stress, whereby the acting comminution produces both a fraction of particles having a sufficiently small size formed by ductile or plastic-like deformation and a remaining fraction of larger particles formed from brittle fracture. Postmortem microscopy is then used to identify the smallest particle size whose morphology indicates it formed from brittle fracture (d B2D ). The brittle material's σ y can then be estimated using a combination of the d B2D , Kendall's and Griffith's theories, a priori knowledge of the material's fracture toughness (K Ic ), and a fracture mechanics shape factor constant (Y) using σ y = √((32 π K Ic 2 )/(3 Y 2 d B2D )). The method's development and its use to estimate σ y for several vitreous silicates, α-quartzes, and NaCl are provided.
Investigating the stability of reoriented hydrides and their reprecipitation using in-situ heating experiments
The behavior of radial hydrides in Zr-2.5Nb pressure tube samples at elevated temperature has been studied. The aim of this work is to investigate the stability of stress-reoriented hydrides under heating without an external applied load. Using in-situ heating at beamline, 1-ID at Argonne National Laboratory, USA, it was shown that two populations of hydrides existed in the sample, naturally oriented and reoriented hydrides. At a relatively low temperature of 180 °C it was observed that the reoriented hydrides completely dissolved, leaving only the naturally oriented hydrides in the sample, when heated without an applied load. On subsequent cooling of the sample, only naturally oriented hydrides were observed. These observations were confirmed using in-situ scanning electron microscopy heating experiments and post-mortem transmission electron microscopy studies. The results presented here offer a potential route for ductility recovery of pressure tube materials where radial hydrides have been shown to significantly reduce fracture toughness of components.
Gradient nanostructured steel with superior tensile plasticity
Nanostructured metallic materials with abundant high-angle grain boundaries exhibit high strength and good radiation resistance. While the nanoscale grains induce high strength, they also degrade tensile ductility. We show that a gradient nanostructured ferritic steel exhibits simultaneous improvement in yield strength by 36% and uniform elongation by 50% compared to the homogenously structured counterpart. In situ tension studies coupled with electron backscattered diffraction analyses reveal intricate coordinated deformation mechanisms in the gradient structures. The outermost nanolaminate grains sustain a substantial plastic strain via a profound deformation mechanism involving prominent grain reorientation. This synergistic plastic co-deformation process alters the rupture mode in the post-necking regime, thus delaying the onset of fracture. The present discovery highlights the intrinsic plasticity of nanolaminate grains and their significance in simultaneous improvement of strength and tensile ductility of structural metallic materials.
Effect of Re and Al additions on the microstructure and mechanical properties of Nb-18Ti-12W alloy
Microstructure and mechanical properties at 25–1200 °C of new refractory alloys, Nb-18Ti-12W (NTW), Nb-18Ti-12W-5Re (NTW-R) and Nb-18Ti-12W-5Re-1Al (NTW-RA), all compositions are in atomic percent, are reported. The alloys are developed as an alternative to a denser, more expensive and difficult-to-process refractory alloy WC-3009. After production by arc melting and hot isostatic pressing at 1400 °C, 207 MPa for 3 h, the alloys have a BCC crystal structure with the average grain size of ~150–200 μm and contain low volume fraction of (Ti,N)-rich precipitates near grain boundaries. NTW shows excellent malleability at all studied temperatures. Its yield stress at 25 °C, 1000 °C and 1200 °C is 874 MPa, 353 MPa and 202 MPa, respectively. The NTW-R and NTW-RA alloys are stronger at all the studied temperatures; however, they lack in compression ductility at 25 °C. As a result, extensive deformation twinning and formation of intergranular voids precede the fracture of these two alloys at 25 °C.
Effect of alloying on intrinsic ductility in WTaCrV high entropy alloys
Tungsten (W) exhibits desirable properties for extreme applications, such as the divertor in magnetic fusion reactors, but its practicality remains limited due to poor formability and insufficient irradiation resistance. In this work, we study the intrinsic ductility of body-centered cubic WTaCrV based high entropy alloys (HEAs), which are known to exhibit excellent irradiation resistance. The ductility evaluations are carried out using a criterion based on the competition between the critical stress intensity factors for emission (K Ie ) and cleavage (K Ic ) in the {110} slip planes and {110} crack planes, which are evaluated within the linear elastic fracture mechanics framework and computed using density functional theory. The results suggest that increasing the alloying concentrations of V and reducing the concentrations of W can significantly improve the ductility in these HEAs. The elastic anisotropy for these HEAs is analyzed using the Zener anisotropy ratio and its correlation with the concentration of W in the alloys is studied. Results indicate that these alloys tend to be fairly isotropic independently from the concentration of W in them. The computed data for the elastic constants of these HEAs is also compared against available experimental data. The results are in good agreement, validating the robustness and accuracy of the computational methods. Multiple phenomenological ductility metrics were also computed and analyzed against the analytical model. Some metrics, mainly the surrogate D parameter, show a good correlation with the Rice model. The potential of these empirical metrics to serve as surrogate screening models for optimizing the compositional space is also discussed.
Material and component developments for the DEMO divertor using fibre reinforcement and additive manufacturing
Within the research along the European Fusion Roadmap, water-cooled divertor PFCs are foreseen in the design of a first fusion demonstration power plant (DEMO) in order to provide reliable heat removal capability. In the frame of this concerted attempt, the Max Planck Institute for Plasma Physics is concentrating on the development and testing of composite materials based on tungsten (W, preferred armour material) and copper (Cu, preferred heat sink material). W fibres (W f ) as monofilaments and yarns as reinforcement play a central role in these investigations due to their extraordinary properties concerning ductility already at room temperature and high tensile strength. Recent investigations on the impact of radiation damage suggest that the fibres retain their ductility upon irradiation. W reinforced with W fibres (W f /W) allows to overcome the intrinsic brittleness of W. Quantitative mechanical fracture tests of W f /W confirm the basic mechanisms of fibre reinforcement and the increased resistance to mechanical fatigue. The good wettability of W with liquid Cu and the absence of any metallurgical solubility make up an ideal material pairing for composite production. W fibre-reinforced Cu (W f /Cu) cooling tubes provide a rather high thermal conductivity (> 250 W mK -1 ) and at least twice the strength of CuCrZr in hoop direction in the temperature range up to at least 500 °C. Very recent neutron irradiation experiments confirm the sustainment of ductility of the W f /Cu composite. Numerical simulations suggest that thermal stresses in W-Cu PFCs could be strongly reduced by tailoring the local W and Cu volume fraction. This 'freely' distributed material composition can be achieved by means of additively manufactured W skeletons consecutively infiltrated by Cu. Investigations with W preforms produced by Laser Beam Powder Bed Fusion and infiltrated by Cu demonstrate the feasibility of this approach while testing of specifically prepared specimen is ongoing.