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DOE OSTI2020

Particle size effects in metallic microparticle impact-bonding

In cold spray processing of metals, the critical velocity for particle bonding is dependent on both intrinsic material properties, such as density and (spall) strength, and extrinsic process parameters, such as the powder particle size. Here, we specifically isolate and investigate particle size effects on the critical velocity for bonding through laser- induced single particle impact experiments and finite element simulations. We also present a predictive framework to correlate particle size and critical velocity. We show that an increase in particle size leads to an increase in the temperature of the jet formed at the interface of the particle and the substrate. This increased temperature locally decreases the spall strength of the material which, in turn, decreases the critical velocity for larger particles.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Dynamic properties of FeCrMnNi, a high entropy alloy

The goal of this paper was to assess the dynamic properties of a new class of materials, High entropy alloys (HEAs). Specifically, gas gun experiments coupled with recovery were performed on a specific HEA, FeCrMnNi, to measure its equation of state (EOS) and its spall strength, which is a measure of the stress required to nucleate voids under shock loading conditions. While there has been a plethora of work performed to assess the mechanical properties of these HEAs under uniaxial stress conditions as a function of strain rate, investigation of its properties in dynamic extremes remains rare. The current work fills this gap in knowledge for this novel class of materials. Our results show that the measured EOS for this material at one velocity was in reasonable agreement with an estimated Hugoniot. Furthermore, while the spall strength for this material was found to be ~1.9 GPa, with some variation based on sample location, the main failure mode was brittle. This brittle failure leading to formation of cracks in the material is different than the ductile failure observed in pure iron and its alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Dynamic response of additively manufactured Ti–5Al–5V–5Mo–3Cr as a function of heat treatment

Both shock and shockless compression experiments were performed on laser powder bed fusion (LPBF) Ti–5Al–5V–5Mo–3Cr (Ti-5553) to peak compressive stresses near 15 GPa. Experiments were performed on the as-built material, containing a purely β (body centered cubic) microstructure, and two differing heat treatments resulting in a dual phase α (hexagonal close packed) and β microstructure. The Hugoniot, Hugoniot elastic limit (HEL), and spallation strength were measured and compared to wrought Ti-6Al-4V (Ti-64). The results indicate the LPBF Ti-5553 Hugoniot response is similar between heat treatments and to Ti-64. The HEL stress observed in the LPBF Ti-5553 was considerably higher than Ti-64, with the as-built, fully β alloy exhibiting the largest values. The spallation strength of the LPBF Ti-5553 was also similar to Ti-64. Clear evidence of initial porosity serving as initiation sites for spallation damage was observed when comparing computed tomography measurements before and after loading. Post-mortem scanning electron microscopy images of the recovered spallation samples showed no evidence of retained phase changes near the spall plane. The spall plane was found to have kinks aligned with the loading direction near areas with large concentrations of twin-like, crystallographic defects in the as-built condition. For the heat-treated samples, the concentrations of twin-like, crystallographic defects were absent, and no preference for failure at the interface between the α and β phases was observed.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Seismoacoustic analysis of underground explosions using the Rayleigh integral

SUMMARY A coupled seismoacoustic model is developed for the analysis of acoustic signals produced by underground explosive events with an aim to develop a means of improving estimated depth and yield for explosion monitoring. A ground spall model is used to predict surface motion characteristics produced by an underground explosion and the Rayleigh integral is applied to relate the surface motion to the acoustic signal some distance from surface ground zero. The low-frequency component of the ground motion associated with the prolonged free fall of lofted material during spall is found to dominate the acoustic signal propagating away from surface ground zero at shallow angles. The model is applied to observed ground motion and acoustic signals recorded during the Source Physics Experiment (SPE) with promising results. In addition to accurately predicting characteristics of the observed acoustic signals from several of the SPE events, the model provides a means of explaining the lack of signals observed during several events in the SPE due to the directionality of the higher frequency acoustic signals associated with the uplift and closure components as well as the lack of a spatially localized, longer duration dwell.

58 GEOSCIENCES↗

DOE OSTI2019

Dynamic Strength of a Eutectic Bismuth–Lead Alloy in the Solid and Liquid States

The dynamic tensile strength (spall strength) of a eutectic bismuth–lead alloy is measured in the solid and liquid states in the temperature range from room temperature to 102°C for the solid phase and in the range 130–150°C for the melt. Melting is found to be accompanied by a decrease in the dynamic tensile strength by almost an order of magnitude. The Hugoniot elastic limit and the spall strength of the alloy in the solid state decrease with increasing test temperature.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2019

Influence of High-Temperature Annealing on the Resistance to High Strain Rate and Fracture of Tantalum at Temperatures of 20 and 500°C

Two series of shock-wave experiments have been conducted in order to measure the Hugoniot elastic limit and determine the strain rate dependence of critical fracture stress for tantalum experiencing spall fracture. Tantalum specimens have been preannealed in vacuum at 1000°C. The evolution of elastoplastic compression shock waves at room and elevated up to 500°C temperatures has been presented from complete wave profiles recorded by a VISAR laser Doppler velocimeter. The spall strength dependence on the strain rate during the expansion of the material in a rarefaction wave has been determined.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Dense Seismic Array Study of a Legacy Underground Nuclear Test at the Nevada National Security Site

The complex postdetonation geologic structures that form after an underground nuclear explosion are difficult to constrain because increased heterogeneity around the damage zone affects seismic waves that propagate through the explosion site. Generally, a vertical rubble-filled structure known as a chimney is formed after an underground nuclear explosion that is composed of debris that falls into the subsurface cavity generated by the explosion. Compared with chimneys that collapse fully, leaving a surface crater, partially collapsed chimneys can have remnant subsurface cavities left in place above collapsed rubble. The 1964 nuclear test HADDOCK, conducted at the Nevada test site (now the Nevada National Security Site), formed a partially collapsed chimney with no surface crater. Understanding the subsurface structure of these features has significant national security applications, such as aiding the study of suspected underground nuclear explosions under a treaty verification. In this study, we investigated the subsurface architecture of the HADDOCK legacy nuclear test using hybrid 2D–3D active source seismic reflection and refraction data. The seismic data were acquired using 275 survey shots from the Seismic Hammer (a 13,000 kg weight drop) and 65 survey shots from a smaller accelerated weight drop, both recorded by ~1000 three-component 5 Hz geophones. First-arrival, P-wave tomographic modeling shows a low-velocity anomaly at ~200 m depth, likely an air-filled cavity caused by partial collapse of the rock column into the temporary postdetonation cavity. A high-velocity anomaly between 20 and 60 m depth represents spall-related compaction of the shallow alluvium. Hints of low velocities are also present near the burial depth (~364 m). The reflection seismic data show a prominent subhorizontal reflector at ~300 m depth, a short-curved reflector at ~200 m, and a high-amplitude reflector at ~50 m depth. Comparisons of the reflection sections to synthetic data and borehole stratigraphy suggest that these features correspond to the alluvium–tuff contact, the partial collapse cavity, and the spalled layer, respectively.

58 GEOSCIENCES↗

DOE OSTI2020

Microstructural Changes to Thermally Sprayed Materials Subjected to Dynamic Compression

Dynamic compression of materials can induce a variety of microstructural changes. As thermally-sprayed materials have highly complex microstructures, the expected pressure at which changes occur cannot be predicted a priori. In addition, typical in-situ measurements such as velocimetry are unable to adequately diagnose microstructural changes such as failure or pore collapse. Quasi-isentropic compression experiments with sample recovery were conducted to examine microstructural changes in thermally sprayed tantalum and tantalum-niobium blends up to 8 GPa pressure. Spall fracture was observed in all tests, and post-shot pore volume decreased relative to the initial state. The blended material exhibited larger spall planes with fracture occurring at interphase boundaries. An estimate of the pressure at which pore collapse is complete was determined to be ~26 GPa for pure tantalum and ~19 GPa for the tantalumniobium blend under these loading conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Mechanical Response of Additively Manufactured Stainless Steel 304L Across a Wide Range of Loading Conditions

The mechanical response of additively manufactured (AM) stainless steel 304L has been investigated across a broad range of loading conditions, covering 11 decades of strain rate, and compared with the behaviors of traditional ingot-derived (wrought) material. In general, the AM material exhibits a greater strength and reduced ductility compared with the baseline wrought form. These differences are consistently found from quasi-static and high strain rate tests. A detailed investigation of the microstructure, the defect structure, the phase, and the composition of both forms reveals differences that may contribute to the differing mechanical behaviors. Compared with the baseline wrought material, dense AM stainless steel 304L has a more complex grain structure with substantial sub-structure, a fine dispersion of ferrite, increased dislocation density, oxide dispersions and larger amounts of nitrogen. In-situ neutron diffraction studies conducted during quasi-static loading suggest that the increased strength of AM material is due to its initially greater dislocation density. The flow strength of both forms is correlated with dislocation density through a square root dependence akin to a Taylor-like relationship. Neutron diffraction measurements of lattice strains also correlate with a crystal plasticity finite element simulations of the tensile test. Other simulations predict a significant degree of elastic and plastic anisotropy due to crystallographic texture. Hopkinson tests at higher strain rates $\dot{ε}$ = 500 and 2500 s -1 ) also show a greater strength for AM stainless steel 304L; although, the differences compared with wrought are reduced at higher strain rates. Gas gun impact tests, including reverse ballistic, forward ballistic and spall tests, consistently reveal a larger dynamic strength in the AM material. The Hugoniot Elastic Limit (HEL) of AM SS 304L exceeds that of wrought material although considerable variability is observed with the AM material. Forward ballistic testing demonstrates spall strengths of AM material (3.27 -- 3.91 GPa) that exceed that of the wrought material (2.63 -- 2.88 GPa). The Hugoniot equation-of-state for AM samples matches archived data for this metal alloy.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Heat transfer through a box beam from an impinging hydrogen flame

An analysis was performed to determine whether a hydrogen jet flame impinging on a tunnel ceiling composed of multiple prestressed steel reinforced concrete box beams could result in permanent damage to the tunnel. The lower layer of the concrete box beam was modeled to determine whether heat reaches the steel reinforcing bars and whether spalling could occur. Heat transfer analysis shows that the temperature remains constant at the location of the steel reinforcing bars after 1.3 minutes of impingement and reaches a maximum of 130°C after 5 minutes. However, assuming a constant impingement for 5 minutes is an over estimation due the existing fire model which includes conservative assumptions. Explosive spalling may occur at a thin layer (~0.05 in. at 50 seconds, 0.1 in. at 5 minutes) at the bottom surface of the concrete box beam, but the steel reinforcing bars will not be exposed to the hydrogen flame.

42 ENGINEERING↗

NASA NTRS1972

Microcraters on lunar rocks.

Lunar microcraters may consist of a central, glass-lined pit, a halo of microfractured material surrounding the pit and a larger, generally concentric, spall area. A classification of microcraters is based on the presence or absence of a pit and a spall. The change from one crater type to another is gradational. Comparison with laboratory experiments indicates that a primary microcrater may be identified by the presence of melted host rock associated with the crater. Most microcraters are the result of the high-speed impact of primary, extralunar particles. Microcratering represents the small-scale end of a continuum of impact cratering as a process.

Hartung, J. B.↗

NASA NTRS1973

Pitting fatigue characteristics of AISI M-50 and super nitralloy spur gears

Two groups of 3.50-in. pitch-diameter spur gears, without tip relief, made from consumable-electrode vacuum-melted (CVM) AISI M-50 steel and CVM super nitralloy (5Ni-2A1) were tested under conditions which produced fatigue pitting. The M-50 gears had fatigue lives approximately 50 percent longer than the super nitralloy gears. Both groups of gears failed by classical rolling-element fatigue at the pitch circle. When the gears were overrun past initial spall formation, the spalled M-50 gear teeth failed by fatigue fracture. The M-50 material had higher wear than the super nitralloy material. Differences in fatigue life and wear were not considered statistically significant.

Townsend, D. P.↗

NASA NTRS1973

A life study of AISI M-50 and Super Nitralloy spur gears with and without tip relief

Tests were conducted at 170 F with groups of 3.5-in.-pitch-diameter spur gear with and without tip relief made of consumable-electrode vacuum melted (CVM) Spur Nitralloy (5Ni-2Al) and CVM AISI M-50 steel. The AISI M-50 gears without tip relief had lives approximately 50 percent longer than the Super Nitralloy gears without tip relief. However, the Super Nitralloy gears with tip relief had lives equal to the AISI M-50 gears without tip relief. The difference in lives were not statistically significant. All gears failed by classical pitting fatigue at the pitch circle. However, the AIAI M-50 gears with tip relief failed by tooth fracture. AISI M-50 gear sets without tip relief having a spalled gear tooth which were deliberately overrun after spalling had occurred, failed by tooth fracture.

Townsend, D. P.↗

NASA NTRS1974

Dynamic oxidation behavior at 1000 and 1100 C of four nickel-base cast alloys, NASA-TRW VIA, B-1900, 713C, and 738X

The superalloys NASA-TRW VIA, B-1900, 713C, and 738X were tested cyclically and isothermally for resistance to oxidation in high velocity gas streams for 100 hours at specimen temperatures of 1000 C and 1100 C. Alloys VIA and B-1900, which were the most oxidation resistant, displayed slight and very similar weight changes and metal losses. Alloy 713C also sustained only slight metal losses, but it exhibited some tendency to spall. Alloy 738X was found to be the most susceptible to cyclic oxidation; this resulted in heavy spalling, which in turn caused high weight losses and high metal losses. Oxidation test results are related to the amounts of chromium aluminum, and the refractory metals in the alloys investigated.

Sanders, W. A.↗

NASA NTRS1973

Crater populations on lunar rocks

Approximately 10,000 microcraters were investigated using binocular microscope techniques on fifteen Apollo 16 rocks: crystalline rocks 60315, 60335, 61156, 62235, 62295, and 68415; breccias 60016, 61015, 61175, 66075, and 69935; and glass surfaces 60015, 60095, 60135, and 64455. Diameter measurements of the central glass-lined pits and surrounding spall zones were made. Ratios of spall to pit diameters may range from 3.0 to 4.5 for different rock surfaces. Crater size distributions obtained for production surfaces confirm and extend to larger crater sizes data published previously. The crater size distribution on lunar rocks in the pit diameter range, 10 to 1000 microns, is shown to depend on the average angle of impact which is a function of the exposure geometry. In contrast to results of earlier studies, a wide range of crater densities was observed on relatively heavily cratered surfaces.

Neukum, G.↗

NASA NTRS1975

Hot corrosion evaluation of aluminide coated superalloys in support of an ASTM Round Robin program

Commercial aluminized coatings on substrates were hot corroded at 900 C in a 0.3 Mach burner rig with 5 ppm synthetic sea salt and at two cycling frequencies. Extensive post-exposure examinations were conducted on the corroded specimens such as metallography, X-ray diffraction, scanning electron microscopy, microprobe raster scans, and spectrographic analyses. Thermodynamic calculations were made of the equilibrium burner flame composition and the calculations were compared to the experimental findings. It was found that localized spalling of the coatings preceded coating failure. It is suggested that the spalling of the coatings is due to the formation of localized stresses caused by the depletion of chromium and aluminum in the coating or the enrichment of the coating with sulfur. For the materials and test conditions investigated, it was found that coating life is dependent only upon the initial coating thickness and not on the type of aluminized coating, the substrate, or the cycle frequency.

Santoro, G.↗

NASA NTRS1976

Microcraters formed in hot glass by hypervelocity projectiles

Microcraters were formed in heated soda-lime glass by the normal incidence of spheres of plastic or fused silica with diameters between 0.8 and 4.5 microns and velocities between 2.5 and 10 km/s. The morphology of the craters in targets at temperatures up to 800 C is little different from those formed in unheated glass. Spallation still occurs to the same extent and above the same velocity threshold, but the spalls sag and sharp edges become dull in a few seconds at temperatures above the softening point. There is a small increase in the flow of glass from the central pit into a narrow lip at the higher temperatures, but this lip is often removed by spallation, especially at the higher velocities of impact. There is no evidence of a splashed lip with strings of melt overlying the spalled area. The results in conjunction with other evidence suggest that most lunar craters of micrometer size with a smooth central pit, splashed lip, and a spallation zone are the result of primary impacts.

Vedder, J. F.↗

NASA NTRS1978

Static and dynamic cyclic oxidation of 12 nickel-, cobalt-, and iron-base high-temperature alloys

Twelve typical high-temperature nickel-, cobalt-, and iron-base alloys were tested by 1 hr cyclic exposures at 1038, 1093, and 1149 C and 0.05 hr exposures at 1093 C. The alloys were tested in both a dynamic burner rig at Mach 0.3 gas flow and in static air furnace for times up to 100 hr. The alloys were evaluated in terms of specific weight loss as a function of time, and X-ray diffraction analysis and metallographic examination of the posttest specimens. A method previously developed was used to estimate specific metal weight loss from the specific weight change of the sample. The alloys were then ranked on this basis. The burner-rig test was more severe than a comparable furnace test and resulted in an increased tendency for oxide spalling due to volatility of Cr in the protective scale and the more drastic cooling due to the air-blast quench of the samples. Increased cycle frequency also increased the tendency to spall for a given test exposure. The behavior of the alloys in both types of tests was related to their composition and their tendency to form scales. The alloys with the best overall behavior formed alpha-Al2O3 aluminate spinels.

Barrett, C. A.↗