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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Location-Dependent Mechanical Property Evaluation on Additively Manufacture Materials

This report summarizes research activities conducted at Argonne National Laboratory in support of the development, qualification and certification of additively manufactured (AM) metallic components to allow for innovative reactor design and licensing for the Transformational Challenge Reactor (TCR). Focus is on the evaluation of high temperature mechanical properties including creep and fatigue of 316L stainless steel manufactured by the laser powder bed fusion process. Creep behavior of AM 316L stainless steel was evaluated for rods printed by either or a combination of both lasers of the dual-laser system of a Concept Laser-M2 printer to examine the consistency across the build plate. Creep tests were conducted at temperatures of 550, 575, 600, and 650°C and stresses between 175 and 300 MPa using ASTM standard-sized specimens. The effect of heat treatments at different temperatures on creep properties of AM 316L SS was examined to understand the processing-microstructure-property relationship. Fatigue properties of AM 316L SS were investigated for two print geometries (rod and plate) and in two build orientations of printed plates. Locations of specimens in the build were carefully tracked such that the testing data can be directly related to location-specific in situ data to establish links between printing process, post-printing treatment, microstructure and mechanical properties. The work is to support the development of a digital platform informed approach to AM component qualification and certification for nuclear applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1985

Investigation of composite materials property requirements for sonic fatigue research

Experimental techniques for determining the extensional and bending stiffness characteristics for symmetric laminates are presented. Vibrational test techniques for determining the dynamic modulus and material damping are also discussed. Partial extensional stiffness results intially indicate that the laminate theory used for predicting stiffness is accurate. It is clearly shown that the laminate theory can only be as accurate as the physical characteristics describing the lamina, which may vary significantly. It is recommended that all of the stiffness characteristics in both extension and bending be experimentally determined to fully verify the laminate theory. Dynamic modulus should be experimentally evaluated to determine if static data adequately predicts dynamic behavior. Material damping should also be ascertained because laminate damping is an order of magnitude greater than found in common metals and can significantly effect the displacement response of composite panels.

Patrick, H. V. L.↗
NASA NTRS1956

Some Observations on the Relationship Between Fatigue and Internal Friction

Results are presented of an investigation made to determine the internal friction and fatigue strength of commercially pure 1100 aluminum under repeated stressing in torsion at various temperatures and stress levels in an effort to find if there exists any correlation between internal friction and fatigue characteristics.

ALUMINUM↗
DOE OSTI2021

Tailoring Microstructure and Mechanical Properties of Additively-Manufactured Ti6Al4V Using Post Processing

Additively-manufactured Ti-6Al-4V (Ti64) exhibits high strength but in some cases inferior elongation to those of conventionally manufactured materials. Post-processing of additively manufactured Ti64 components is investigated to modify the mechanical properties for specific applications while still utilizing the benefits of the additive manufacturing process. The mechanical properties and fatigue resistance of Ti64 samples made by electron beam melting were tested in the as-built state. Several heat treatments (up to 1000 °C) were performed to study their effect on the microstructure and mechanical properties. Phase content during heating was tested with high reliability by neutron diffraction at Los Alamos National Laboratory. Two different hot isostatic pressings (HIP) cycles were tested, one at low temperature (780 °C), the other is at the standard temperature (920 °C). The results show that lowering the HIP holding temperature retains the fine microstructure (~1% β phase) and the 0.2% proof stress of the as-built samples (1038 MPa), but gives rise to higher elongation (~14%) and better fatigue life. The material subjected to a higher HIP temperature had a coarser microstructure, more residual β phase (~2% difference), displayed slightly lower Vickers hardness (~15 HV10N), 0.2% proof stress (~60 MPa) and ultimate stresses (~40 MPa) than the material HIP’ed at 780 °C, but had superior elongation (~6%) and fatigue resistance. Heat treatment at 1000 °C entirely altered the microstructure (~7% β phase), yield elongation of 13.7% but decrease the 0.2% proof-stress to 927 MPa. The results of the HIP at 780 °C imply it would be beneficial to lower the standard ASTM HIP temperature for Ti6Al4V additively manufactured by electron beam melting.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fatigue-crack propagation behavior in a high-carbon chromium SUJ2 bearing steel: Role of microstructure

High-carbon chromium martensite steels are commonly selected for bearing components in the power generation, automotive and aerospace industries where fatigue failure is a major concern. Accordingly, it is of importance to elucidate the structure-property relationships governing the fatigue properties of such bearing steels. Here, the role of microstructure in influencing the fatigue-crack propagation behavior of a high-carbon chromium SUJ2 bearing steel is examined with emphasis on three martensitic structures: (i) a fine-grained (~10 μm) structure with intragranular (but no intergranular) carbides, (ii) a coarser-grained (~25 μm) structure with discontinuous grain-boundary carbides primarily near triple junctions, and (iii) a coarse-grained (~31 μm) structure with continuous grain-boundary carbides. Although growth rates were fairly similar above ~10 -8 m/cycle, significant differences in behavior were observed at lower, near-threshold growth rates; specifically at a load ratio of 0.1, the ΔKth fatigue threshold was increased from 3.8 MPa m ½ in the fine-grained structure to 5.9 to 6.3 MPa m ½ in the two coarser-grained structures. The dominant factor governing such near-threshold behavior was found to be crack-tip shielding from roughness-induced crack closure, which was most pronounced in the coarser-grained structures; additionally, shielding from crack deflection and branching was apparent in these structures as the crack propagated through the network of intersecting martensite lamellae within the coarse grains. Compared to high-strength stainless steels and low-strength carbon steels, the fine-grained SUJ2 steel displays an exceptional combination of high strength and fatigue-crack growth resistance and is considered to be a superior structural alloy for bearing applications.

36 MATERIALS SCIENCE↗
NASA NTRS1955

Some observations on loss of static strength due to fatigue cracks

Static tensile tests were performed on simple notched specimens containing fatigue cracks. Four types of aluminum alloys were investigated: 2024-T3(formerly 24S-T3) and 7075-T6(formerly 75S-T6) in sheet form, and 2024-T4(formerly 24S-T4) and 7075-T6(formerly 75S-T6) in extruded form. The cracked specimens were tested statically under four conditions: unmodified and with reduced eccentricity of loading by three methods. Results of static tests on C-46 wings containing fatigue cracks are also reported.

MATERIALS, PROPERTIES - FATIGUE↗
NASA NTRS1990

Fatigue damage growth mechanisms in continuous fiber reinforced titanium matrix composites

The role of fiber/matrix interface strength, residual thermal stresses, and fiber and matrix properties on fatigue damage accumulation in continuous fiber metal matrix composites (MMC) is discussed. Results from titanium matrix silicon carbide fiber composites is the primary topic of discussion. Results were obtained from both notched and unnotched specimens at room and elevated temperatures. The stress in the 0 deg fibers was identified as the controlling factor in fatigue life. Fatigue of the notched specimens indicated that cracks can grow in the matrix materials without breaking fibers.

Johnson, W. S.↗
NASA NTRS1990

Fatigue damage growth mechanisms in continuous fiber reinforced titanium matrix composites

The role of fiber/matrix interface strength, residual thermal stresses, and fiber and matrix properties on fatigue damage accumulation in continuous fiber metal matrix composites (MMC) will be discussed. Results from titanium matrix/silicon-carbide fiber composites will be the primary topic of discussion. Results have been obtained from both notched and unnotched specimens at room and elevated temperatures. The stress in the 0 deg fibers has been indentified as the controlling factor in fatigue life. Fatigue of the notched specimens indicated that cracks can grow many fiber spacings in the matrix materials without breaking fibers.

Johnson, W. S.↗
NASA NTRS1972

Examination of the influence of coatings on thin superalloy sections

The effects of two coatings, Codep B-1 and CoCrAlY, with and without simulated engine exposures at 982 C (1800 F) and 1093 C (2000 F), were evaluated on cast sections of Rene 80. Section thicknesses were from 0.075 cm (0.030 inch) to 0.15 cm (0.060 inch). Tensile and stress rupture properties, mechanical fatigue, thermal fatigue, ballistic impact and hot corrosion at R. T. and elevated temperatures were investigated. Thin sections generally had poorer tensile strengths and lower stress rupture lives than standard 1/4 inch round gage bars. The coatings, as-applied, had little effect on tensile strengths, rupture lives and mechanical fatigue and they increased thermal fatigue, ballistic impact and hot corrosion resistance. By providing considerable exposure protection to the Rene 80, the coatings improved all properties compared to exposed bare specimens.

Kaufman, M.↗
DOE OSTI2021

Quasi-Static Time Series Fatigue Simulation for PV Inverter Semiconductors with Long-Term Solar Profile

Power system simulations with long-term data tend to have large time steps varying from one second to a few minutes. However, for PV inverter semiconductors, the minimum thermal stresses cycle is with line frequency. This requires the time step of the fatigue simulation to be much smaller than the line period. This small time step results in poor simulation speed, especially for long-term simulations. This paper proposes a fast fatigue simulation for inverter semiconductors using the quasi-static time series (QSTS) simulation concept. The fatigue analysis typically focuses on the peak and valley values of a strain and neglect the transients from peaks to valleys. The proposed simulation utilizes this property of fatigue analysis and calculates the steady state of the semiconductor junction temperature only. The resulting time step of the fatigue simulation is 15 minutes, which is consistent with the solar dataset without losing accuracy.

fast simulation↗
NASA NTRS2011

Increased Mechanical Properties Through the Addition of Zr to GRCop-84

GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) has shown exceptional mechanical properties above 932 F (773 K). However, its properties below 932 F (773 K) are inferior to precipitation strengthened alloys such as Cu-Cr, Cu-Zr and Cu-Cr-Zr when they are in the fully aged, hard-drawn condition. It has been noted that the addition of small amounts of Zr, typically 0.1 wt.% to 0.5 wt.%, can greatly enhance the mechanical properties of copper-based alloys. Limited testing was conducted upon GRCop-84 with an addition of 0.4 wt.% Zr to determine its tensile, creep and low cycle fatigue (LCF) properties. Very large increases in strength (up to 68%) and ductility (up to 123%) were observed at both room temperature and 932 F (773 K). Creep properties at 932 F (773 K) demonstrated more than an order of magnitude decrease in the creep rate relative to unmodified GRCop-84 with a corresponding order of magnitude increase in creep life. Limited LCF testing showed that the modified alloy had a comparable LCF life at room temperature, but it was capable of sustaining a much higher load. While more testing and composition optimization are required, the addition of Zr to GRCop-84 has shown clear benefits to mechanical properties.

Ellis, David L.↗
NASA NTRS1957

Stress-life relation of the rolling-contact fatigue spin rig

The rolling-contact fatigue spin rig was used to test groups of SAE 52100 9.16-inch-diameter balls lubricated with a mineral oil at 600,000-, 675,000-, and 750,000-psi maximum Hertz stress. Cylinders of AISI M-1 vacuum and commercial melts and MV-1 (AISI M-50) were used as race specimens. Stress-life exponents produced agree closely with values accepted in industry. The type of failure obtained in the spin rig was similar to the subsurface fatigue spells found in bearings.

SURFACES, CONTACT - ROLLING↗
NASA NTRS2002

Evaluation of Fatigue Crack Growth and Fracture Properties of Cryogenic Model Materials

The criteria used to prevent failure of wind-tunnel models and support hardware were revised as part of a project to enhance the capabilities of cryogenic wind tunnel testing at NASA Langley Research Center. Specifically, damage-tolerance fatigue life prediction methods are now required for critical components, and material selection criteria are more general and based on laboratory test data. The suitability of two candidate model alloys (AerMet 100 and C-250 steel) was investigated by obtaining the fatigue crack growth and fracture data required for a damage-tolerance fatigue life analysis. Finally, an example is presented to illustrate the newly implemented damage tolerance analyses required of wind-tunnel model system components.

Newman, John A.↗
NASA NTRS1956

Interim Report on Fatigue Characteristics of a Typical Metal Wing

Constant amplitude fatigue tests of seventy-two P-51D "Mustang" wings are reported. The tests were performed by a vibrational loading system and by an hydraulic loading device for conditions with and without varying amounts of pre-load. The results indicate that: (a) the frequency of occurrence of fatigue at any one location is related to the range of the loads applied, (b) the rate of propagation of visible cracks is more or less constant for a large portion of the life of the specimen, (c) the fatigue strength of the structure is similar to that of notched material having a theoretical stress concentration factor of more than 3.0, (d) the frequency distribution of fatigue life is approximately logarithmic normal, (e) the relative increase in fatigue life for a given pre-load depends on the maximum load of the loading cycle only, while the optimum pre-load value is approximately 85 percent of the ultimate failing load, and (f) that normal design procedure will not permit the determination of local stress levels with sufficient accuracy to determine the fatigue strength of an element of a redundant structure.

LOADS AND STRESSES, STRUCTURAL - REPEATED DYNAMIC↗
NASA NTRS1983

Cryogenic fluid management experiment trunnion fatigue verification

A subcritical liquid hydrogen orbital storage and transfer experiment was designed for flight in the Shuttle cargo bay. The Cryogenic Fluid Management Experiment (CFME) includes a liquid hydrogen tank supported in a vacuum jacket by two fiberglass epoxy trunnion mounts. This composite material was selected for the trunnions since it provides desirable strength, weight and thermal characteristics for supporting cryogenic tankage. An experimental program was conducted to provide material property and fatigue data for S-glass epoxy composite materials at ambient and liquid hydrogen temperatures and to verify structural integrity of the CFME trunnion supports.

Bailey, W. J.↗
DOE OSTI2022

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. In this work, we develop Machine Learning (ML) models that can use in-situ thermographic data to predict the micropore of LPBF stainless steel materials. This work considers two identified key features from the thermal histories: the time above the apparent melting threshold ($\tau$) and the maximum radiance ( T max ). These features are computed, stored for each voxel in the built material, and then used as inputs. The binary state of each voxel, either defective or normal, is the output. Different ML models are trained and tested for the binary classification task. In addition to using the thermal features of each voxel to predict its own state, the thermal features of neighboring voxels are also included as inputs. This is shown to improve the prediction accuracy, which is consistent with thermal transport physics around each voxel contributing to its final state. Among the models trained, the F1 scores on test sets reach above 0.96 for Random Forests. Feature importance analysis based on the ML models shows that T max is more important to the voxel state than $\tau$ . The analysis also finds that the thermal history of the voxels above the present voxel is more influential than those beneath it. Our study significantly extends the capability of using in-situ thermographic data to predict porosity in LPBF materials. Finally, since ML models are fast, they may play integral roles in the optimization and control of such AM technologies.

36 MATERIALS SCIENCE↗