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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.

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At least 181 records · Page 10

Recent Developments in the Use of Liquid Crystal Coatings for Full-Surface Shear Stress Vector Measurements

Under normal white-light illumination and oblique observation, liquid crystal coating (LCC) color-change response to shear depends on both shear stress magnitude as well as the direction of the applied shear relative to the observer's line of sight. These color-change responses were quantified by subjecting a LCC to a wall-jet shear flow and measuring scattered-light spectra using a fiber optic probe and spectrophotometer. At any fixed shear stress magnitude, the maximum color change was measured when the shear vector was aligned with and directed away from the observer; changes in the relative in-plane view angle to either side of this vector/observer aligned position resulted in symmetric Gaussian reductions in measured color change. For this vector/observer aligned orientation, color change was found to scale linearly with increasing shear stress magnitude over an eight-fold range. Based on these results, a surface shear stress vector measurement methodology, involving multiple oblique-view observations of the test surface, was formulated. In the present paper, the experimental approach and data analysis procedure required to extend this vector measurement methodology to full-surface applications will be outlined and progress towards demonstrating this areal capability will be reviewed.

Reda, D. C.↗

Strain Measurement during Stress Rupture of Composite Over-Wrapped Pressure Vessel with Fiber Bragg Gratings Sensors

Fiber optic Bragg gratings were used to measure strain fields during Stress Rupture (SSM) test of Kevlar Composite Over-Wrapped Pressure Vessels (COPV). The sensors were embedded under the over-wrapped attached to the liner released from the Kevlar and attached to the Kevlar released from the liner. Additional sensors (foil gages and fiber bragg gratings) were surface mounted on the COPY liner.

Banks, Curtis E.↗

Laser Interferometer Skin-Friction measurements of crossing-shock wave/turbulent boundary-layer interactions

Wall shear stress measurements beneath crossingshock wave/turbulent boundary-layer interactions have been made for three interactions of different strengths. The interactions are generated by two sharp fins at symmetric angles of attack mounted on a flat plate. The shear stress measurements were made for fin angles of 7 and 11 degrees at Mach 3 and 15 degrees at Mach 4. The measurements were made using a Laser Interferometer Skin Friction (LISF) meter; a device which determines the wail shear by optically measuring the time rate of thinning of an oil film placed on the test model surface. Results of the measurements reveal high skin friction coefficients in the vicinity of the fin/plate junction and the presence of quasi-two-dimensional flow separation on the interaction centerline. Additionally, two Navier-Stokes computations, one using a Baldwin-Lomax turbulence model and one using a k-~ model, are compared to the experimental results for the Mach 4, 15 degree interaction case. While the k-~ model did a reasonable job of predicting the overall trend in portions of the skin friction distribution, neither computation fully captured the physics of the near surface flow in this complex interaction.

Garrison, T. J.↗

Spherical Nanoindentation Stress-Strain Measurements of BOR-60 14YWT-NFA1 Irradiated Tubes

Spherical nanoindentation stress-strain protocols were applied to characterize unirradiated and fast neutron irradiated nanostructured ferritic alloy (NFA) 14YWT and compared against Berkovich nanohardness and available tensile data. The predicted uniaxial yield strength from spherical, 100 and 5 micron radii, indentation yield strength measurements was 1100-1400 MPa which compares well with the predictions from Berkovich nanohardness, 1200 MPa, and available tensile data, ~1100 MPa. However, spherical indentation measurements predict an increase in the uniaxial yield strength of ~1 GPa while Berkovich nanohardness measurements predict an increase of only ~250 MPa. No tensile data exists on the irradiated condition. It is believed the difference in the predicted uniaxial yield strength between spherical and Berkovich nanoindentation are due to a low number of tests on the irradiated sample combined with the significant heterogeneity in the microstructure, the differences in sensitivity to sample preparation on the irradiated sample between the two indentation protocols , and/or in how strain localizes under the indenter with the possibility of dislocation channeling under Berkovich hardness indents leading to strain softening. Nanoindentation capabilities to test neutron irradiated samples in a radiological area were realized.

36 MATERIALS SCIENCE↗

Modulus of Elasticity and Thermal Expansion Coefficient of ITO Film

The purpose of this experiment was to determine the modulus of elasticity (E) and thermal expansion coefficient (α) of RF sputtered Indium Tin Oxide (ITO) as a function of temperature (T), and to collect ITO film stress data. In order to accomplish that goal, the Toho FLX-2320-S thin film stress measurement machine was used to collect both single stress and stress-temperature data for ITO coated fused silica and sapphire substrates. The stress measurement function of the FLX-2320-S cannot be used to calculate the elastic modulus of the film because the Stoney formula incorporates the elastic modulus of the substrate, rather than of the film itself.

36 MATERIALS SCIENCE↗

Correlation of predicted and measured thermal stresses on a truss-type aircraft structure

A test structure representing a portion of a hypersonic vehicle was instrumented with strain gages and thermocouples. This test structure was then subjected to laboratory heating representative of supersonic and hypersonic flight conditions. A finite element computer model of this structure was developed using several types of elements with the NASA structural analysis (NASTRAN) computer program. Temperature inputs from the test were used to generate predicted model thermal stresses and these were correlated with the test measurements.

Jenkins, J. M.↗

Multiplexing Focusing Analyzer for Efficient Stress-Strain Measurements

Statement of the problem or situation that is being addressed. Although thermal and cold neutron scattering is widely used and is critical for success in many areas of materials science and engineering, relatively low neutron fluxes severely limit applications of not only laboratory neutrons generators, but also large national neutron facilities. State-of-the-art thermal and cold neutron sources are large expensive national facilities, which serve diverse community of scientific and industrial users. The constant need to improve the instruments performance, stems from the fact that neutron methods are gaining in popularity, and becoming more and more powerful, while new neutron sources are not being constructed to keep pace with the developments and needs of the scientific community. Small research reactors at universities and National Labs, and laboratory-based neutron generators, are necessary not only for education and training, but also when samples cannot be transported to other facilities. However, the standard neutron techniques, which were developed for high-flux facilities, require much higher efficiencies to be used effectively with the low fluxes of small sources. Thus, the efficient use of neutron sources, such as with our proposed analyzer, is important for the progress and broader use of these neutron techniques. General statement of how this problem is being addressed. We propose to design and demonstrate novel diffractive optical device, which will enable very efficient residual stress neutron diffractometers. The proposed device will be a multi-foil analyzer, where each foil is constructed of focusing bent single crystals of Si. Such device will enable polychromatic residual stress neutron diffraction. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast measurements for determining residual stress tensors, raster large samples or screen multiple samples. Commercial Applications and Other Benefits The outcome of this project would be the demonstration of commercial devices, novel neutron optical components, which could be utilized to improve the performance of existing instruments or build novel neutron scattering instruments at DOE neutron facilities and commercial laboratory neutron sources. These new devices will widen the scope of research conducted using neutrons and enable measurements not feasible at present. Summary for Members of Congress Thermal and cold neutron beams are a powerful materials science probe, which provide unique information about the structure of matter. The proposed innovations expand the reach of neutron-based investigations to new materials and industries by enabling new instrumentation capabilities, thereby greatly enhancing and expanding the role of small, laboratory-based neutron instrumentation, and improving education and training of neutron users.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Modeling and Measuring the Stress Distribution in Soft Magnetic Cores due to Epoxy Impregnation and Curing

Understanding the effects of viscoelastic relaxation of stresses is critical in electric motor and inductor applications, where the magnetic material is fully or partially comprised of an amorphous phase and impregnated in an epoxy. Magnetic Amorphous Nanocomposites (MANCs) are a class of recently developed high-frequency magnetic materials that exhibit low magnetic hysteresis, high saturation flux density and very low AC magnetic losses. MANCs are formed as long, thin ribbons, a shape factor that minimizes eddy current-induced self-heating. This feature, in addition to their 1 GPa strength, and makes them attractive candidates for high-speed, high-power density, electric motors. MANCs are used in the form of tape-wound cores (TWCs). During the manufacturing process, the cores are impregnated with liquid epoxy between each layer of ribbon. Validated knowledge of the stresses imposed by the manufacturing process and during operation is necessary to understand motor performance limitations with respect to strength. Magnetostriction, the strain imposed by reversal of the magnetic field, also affects performance. When the epoxy cures, it contracts volumetrically by 8%, imposing radial and circumferential stresses that vary along the radial direction. To date, these stresses have received little attention in the literature. Here, we model the stress distribution throughout a TWC due to epoxy curing. Strain gauge measurements reported here indicate substantially lower tangential strain than model values, which is beneficial and which we attribute to viscoelastic relaxation of the epoxy layers. We will incorporate a constitutive model of this viscoelastic relaxation, and conduct more detailed strain measurements to understand how this takes

24 POWER TRANSMISSION AND DISTRIBUTION↗

Organizational stress and individual strain: A social-psychological study of risk factors in coronary heart disease among administrators, engineers, and scientists

It is hypothesized that organizational stresses, such as high quantitative work load, responsibility for persons, poor relations with role senders, and contact with alien organizational territories, may be associated with high levels of psychological and physiological strain which are risk factors in coronary heart disease. It is further hypothesized that persons with coronary-prone Type A personality characteristics are most likely to exhibit strain under conditions of organizational stress. Measures of these stresses, personality traits, and strains were obtained from 205 male NASA administrators, engineers, and scientists. Type A personality measures included sense of time urgency, persistence, involved striving, leadership, and preference for competitive and environmentally overburdening situations.

Caplan, R. D.↗

A comparison of measured and calculated thermal stresses in a hybrid metal matrix composite spar cap element

A hybrid spar of titanium with an integrally brazed composite, consisting of an aluminum matrix reinforced with boron-carbide-coated fibers, was heated in an oven and the resulting thermal stresses were measured. Uniform heating of the spar in an oven resulted in thermal stresses arising from the effects of dissimilar materials and anisotropy of the metal matrix composite. Thermal stresses were calculated from a finite element structural model using anisotropic material properties deduced from constituent properties and rules of mixtures. Comparisons of calculated thermal stresses with measured thermal stresses on the spar are presented. It was shown that failure to account for anisotropy in the metal matrix composite elements would result in large errors in correlating measured and calculated thermal stresses. It was concluded that very strong material characterization efforts are required to predict accurate thermal stresses in anisotropic composite structures.

Jenkins, J. M.↗

Stratigraphically Controlled Stress Variations at the Hydraulic Fracture Test Site-1 in the Midland Basin, TX

We investigated the relationship between stratigraphy, stress, and microseismicity at the Hydraulic Fracture Test Site-1. The site comprises two sets of horizontal wells in the Wolfcamp shale and a deviated well drilled after hydraulic fracturing. Regional stresses indicate normal/strike-slip faulting with E-W compression. Stress measurements in vertical and horizontal wells show that the minimum principal stress varies with depth. Strata with high clay and organic content show high values of the least compressive stress, consistent with the theory of viscous stress relaxation. By integrating data from core, logs, and the hydraulic fracturing stages, we constructed a stress profile for the Wolfcamp sequence, which predicts how much pressure is required for hydraulic fracture growth. We applied the results to fracture orientation data from image logs to determine the population of pre-existing faults that are expected to slip during stimulation. We also determined microseismic focal plane mechanisms and found slip on steeply dipping planes striking NW, consistent with the orientations of potentially active faults predicted by the stress model. This case study represents a general approach for integrating stress measurements and rock properties to predict hydraulic fracture growth and the characteristics of injection-induced microseismicity.

microseismicity↗

Initial study of notch sensitivity of Grade 91 using mechanisms motivated crystal plasticity finite element method

This report describes the development of a crystal plasticity finite element method (CPFEM) model for the multiaxial creep rupture of Grade 91 steel. The report demonstrates that core blocks in heat pipe reactor designs will see significantly different stress states than those typically found in conventional advanced reactor components where structures can often be represented as thin-walled pressure vessels. Current design practice uses effective stress measures calibrated to biaxial creep test data to account for the effect of stress multiaxiality on rupture life. Because these models rely on biaxial data they may not be accurate for the truly 3D, triaxial states found in heat pipe microreactor core blocks. A physically-based model, like the CPFEM model developed here, may be able to more accurately represent creep rupture under triaxial stresses when compared to conventional, empirical methods. This report describes the development, implementation, and validation of such a model and then applies the model to predict the effect of stress triaxiality on rupture in Grade 91 steel. The model results are used to assess the effective stress measures currently used in high temperature design codes and makes specific recommendations on improving these effective stresses to better account for the effect of 3D stress states on rupture in Grade 91. The validation and then implementation of these recommendations in design codes and standards could lead to safer, more effective heat pipe microreactor core block designs.

36 MATERIALS SCIENCE↗

Measurement of Residual Stresses in Different Thicknesses of Laser Shock Peened Aluminium Alloy Samples

This study focused on depth-resolved residual stress results determined with a number of complementary techniques on Laser Shock Peening (LSP) treated aluminium alloy 7075-T651 samples with different thicknesses (6 mm and 1.6 mm). Samples were prepared from a single commercially produced rolled plate that was then treated with LSP. Residual stresses were measured using Laboratory X-Ray Diffraction (LXRD), Incremental Hole Drilling (IHD), Neutron Diffraction (ND) and Synchrotron XRD (SXRD). The LSP treatment resulted in the establishment of compressive residual stresses that varied rapidly in the near surface region. The compressive stresses extended up to 1.5 mm in depth in the 6 mm thick sample. Some surface stress relaxation was observed in the first 25 μm, but substantially large stresses existed at 50 mu m. Finally, this investigation strongly motivated why residual stress profiles should be obtained using a variety of techniques.

36 MATERIALS SCIENCE↗

Validation Data for Benchmarking Wire Arc Additive Manufacturing Process Simulations

Residual stresses cause geometric distortion and affect mechanical performance of additively manufactured structures, yet they are notoriously difficult to assess and predict. Distortion (warpage) can drive parts outside dimensional tolerance limits, leading to part rejection or rework. For parts that meet tolerance, locked-in residual stress fields can affect structural integrity during operation, particularly subcritical cracking by fatigue, creep, or corrosion. This work develops benchmark data for a common additive manufacturing process (Wire Arc Additive Manufacturing) that can be applied for calibration and validation of physical process models that predict residual stress fields. The work includes design of two different samples of differing geometry, detailed manufacturing records for a set of physical samples, and an extensive set of residual stress measurement data developed using two diverse techniques (the contour method and neutron diffraction). An initial application of the work is also reported, where a modeling challenge was issued to secure residual stress model predictions from two independent laboratories that were blind to residual stress measurement data. These initial blind residual stress predictions show significant discrepancies relative to the measurement data, illustrating the potential value of the underlying validation data. An open repository for this work, including the sample designs, manufacturing process records, and the residual stress data, is also provided for future application in non-blind validation efforts.

36 MATERIALS SCIENCE↗

X-ray measurements of stresses and defects in EFG and large grained polycrystalline silicon ribbons

The Bond method was employed to measure the lattice parameter in an area of 0.4 mm in diameter of EFG Si-ribbons to an accuracy of + or - 0.00008 A. A Bond goniometer was built which included a goniostat with a special specimen holder to mount ribbons 1 m in length and 75 mm in width which could be rotated about two orthogonal axes, and a Leitz microscope for precision alignment of a particular area into the center of the goniostat and the small primary X-ray beam. The (321) planes were found to be parallel to the surface of the ribbons with an angular spread of about 15 deg. The poles of the (111) planes clustered about an angle of 25 deg away from the surface normal, again with a spread of 10 deg. The lattice parameter of a small piece of ribbon material was found to be a sub o = 5.43075 A. A maximum stress of 115 MPa was observed in a fractured ribbon which corresponded to the fracture stress of single crystals of Si.

Wagner, C. N. J.↗

Epitaxy and stress of MgO/GaAs(001) heterostructures

We report on the preparation of epitaxial MgO film on GaAs(001) substrates by molecular beam epitaxy at growth temperature of 20–200 °C. Reflection high energy electron diffraction, x-ray diffraction, and high resolution transmission electron microscopy reveal the growth of ordered crystalline cubic MgO(001) film at ∼200 °C with MgO(001)[100]|| GaAs(001)[100] and a 4 : 3 lattice registry. The surface of the MgO films, characterized by atomic force microscopy, exhibits a root mean square roughness of only 0.5 nm. In situ stress measurements reveal tensile stress as low as 1.7 GPa for a growth temperature of 200 °C in good agreement with the calculated residual misfit strain.

36 MATERIALS SCIENCE↗

Comparison of measured temperatures, thermal stresses and creep residues with predictions on a built-up titanium structure

Temperature, thermal stresses, and residual creep stresses were studied by comparing laboratory values measured on a built-up titanium structure with values calculated from finite-element models. Several such models were used to examine the relationship between computational thermal stresses and thermal stresses measured on a built-up structure. Element suitability, element density, and computational temperature discrepancies were studied to determine their impact on measured and calculated thermal stress. The optimum number of elements is established from a balance between element density and suitable safety margins, such that the answer is acceptably safe yet is economical from a computational viewpoint. It is noted that situations exist where relatively small excursions of calculated temperatures from measured values result in far more than proportional increases in thermal stress values. Measured residual stresses due to creep significantly exceeded the values computed by the piecewise linear elastic strain analogy approach. The most important element in the computation is the correct definition of the creep law. Computational methodology advances in predicting residual stresses due to creep require significantly more viscoelastic material characterization.

Jenkins, Jerald M.↗