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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 OSTI2013

Extracting strength from high pressure ramp-release experiments

Unloading from a plastically deformed state has long been recognized as a sensitive measure of a material's deviatoric response. In the case of a ramp compression and unload, time resolved particle velocity measurements of a sample/window interface may be used to gain insight into the sample material's strength. Unfortunately, measurements of this type are often highly perturbed by wave interactions associated with impedance mismatches. Additionally, wave attenuation, the finite pressure range over which the material elastically unloads, and rate effects further complicate the analysis. Here, we present a methodology that overcomes these shortcomings to accurately calculate a mean shear stress near peak compression for experiments of this type. A new interpretation of the self-consistent strength analysis is presented and then validated through the analysis of synthetic data sets on tantalum to 250 GPa. The synthetic analyses suggest that the calculated shear stresses are within 3% of the simulated values obtained using both rate-dependent and rate-independent constitutive models. Window effects are addressed by a new technique referred to as the transfer function approach, where numerical simulations are used to define a mapping to transform the experimental measurements to in situ velocities. The transfer function represents a robust methodology to account for complex wave interactions and a dramatic improvement over the incremental impedance matching methods traditionally used. The technique is validated using experiments performed on both lithium fluoride and tantalum ramp compressed to peak stresses of 10 and 15 GPa, respectively. In each case, various windows of different shock impedance are used to ensure consistency within the transfer function analysis. The data are found to be independent of the window used and in good agreement with previous results.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Interim Development of new Class B Code Case with Variable Design Lifetime and enhanced design rules to guard against cyclic structural failure mode

This report summarizes updates on the ongoing development of the new American Society of Mechanical Engineers Section III, Division 5, Class B rules to address the potential failure modes of Class B components. An initial design-by-analysis approach and supporting design rules are presented. The elastic-perfectly plastic (EPP) analysis approach has been adopted for primary stress limit and ratcheting check to prevent the component failure against the structural failure mode against primary load and strain accumulation due to cyclic loads. The creep-fatigue damage assessment uses explicitly defined elastic follow-up calculated from the stress concentration region of given component. Damage fraction calculation uses a novel coupled approach to capture the influence of the elastic follow-up and provide adequate conservatism for Class B components. The proposed Class B rules does not use the stress classification approach and uses the combined loads to assess component.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Testing and Analysis for Lifetime Prediction of Crystalline Silicon PV Modules Undergoing Degradation by System Voltage Stress: Preprint

Acceleration factors are calculated for crystalline silicon PV modules under system voltage stress by comparing the module power during degradation outdoors to that in accelerated testing at three temperatures and 85% relative humidity. A lognormal analysis is applied to the accelerated lifetime test data considering failure at 80% of the initial module power. Activation energy of 0.73 eV for therate of failure is determined, and the probability of module failure at an arbitrary temperature is predicted. To obtain statistical data for multiple modules over the course of degradation in-situ of the test chamber, dark I-V measurements are obtained and transformed using superposition, which is found well suited for rapid and quantitative evaluation of potential-induced degradation. It isdetermined that shunt resistance measurements alone do not represent the extent of power degradation. This is explained with a two-diode model analysis that shows an increasing second diode recombination current and ideality factor as the degradation in module power progresses. Failure modes of the modules stressed outdoors are examined and compared to those stressed in accelerated tests.

14 SOLAR ENERGY↗
DOE OSTI2015

A phase field dislocation dynamics model for a bicrystal interface system: An investigation into dislocation slip transmission across cube-on-cube interfaces

In this study, we present a phase field dislocation dynamics formulation designed to treat a system comprised of two materials differing in moduli and lattice parameters that meet at a common interface. We apply the model to calculate the critical stress τ crit required to transmit a perfect dislocation across the bimaterial interface with a cube-on-cube orientation relationship. The calculation of τ crit accounts for the effects of: 1) the lattice mismatch (misfit or coherency stresses), 2) the elastic moduli mismatch (Koehler forces or image stresses), and 3) the formation of the residual dislocation in the interface. Our results show that the value of τ crit associated with the transmission of a dislocation from material 1 to material 2 is not the same as that from material 2 to material 1. Dislocation transmission from the material with the lower shear modulus and larger lattice parameter tends to be easier than the reverse and this apparent asymmetry in τ crit generally increases with increases in either lattice or moduli mismatch or both. In efforts to clarify the roles of lattice and moduli mismatch, we construct an analytical model for τcrit based on the formation energy of the residual dislocation. We show that path dependence in this energetic barrier can explain the asymmetry seen in the calculated τ crit values.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Calculation of reinforced-concrete frame strength under a simultaneous static cross section load and a column lateral impact

When designing buildings with reinforced concrete that are planned to resist dynamic loads it is necessary to calculate this structural behavior under operational static and emergency impact and blast loads. Calculations of the structures under shock-wave loads can be performed by solving dynamic equations that do not consider static loads. Due to this fact the calculation of reinforced concrete frame under a simultaneous static and dynamic load in full 3d settings becomes a very non trivial and resource consuming problem. This problem can be split into two tasks. The first one is a shock-wave problem that can be solved using software package RANET-3, which allows solving the problem using finite elements method adapted for dynamic task. This method calculates strain-stress state of the material and its dynamic destruction, which is considered as growth and consolidation of micro defects under loading. On the second step the results of the first step are taken as input parameters for quasi static calculation of simultaneous static and dynamic load using finite elements method in AMP Civil Engineering-11.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Fourier decomposition of polymer orientation in large-amplitude oscillatory shear flow

In our previous work, we explored the dynamics of a dilute suspension of rigid dumbbells as a model for polymeric liquids in large-amplitude oscillatory shear flow, a flow experiment that has gained a significant following in recent years. We chose rigid dumbbells since these are the simplest molecular model to give higher harmonics in the components of the stress response. We derived the expression for the dumbbell orientation distribution, and then we used this function to calculate the shear stress response, and normal stress difference responses in large-amplitude oscillatory shear flow. In this paper, we deepen our understanding of the polymer motion underlying large-amplitude oscillatory shear flow by decomposing the orientation distribution function into its first five Fourier components (the zeroth, first, second, third, and fourth harmonics). We use three-dimensional images to explore each harmonic of the polymer motion. Our analysis includes the three most important cases: (i) nonlinear steady shear flow (where the Deborah number λω is zero and the Weissenberg number λγ 0 is above unity), (ii) nonlinear viscoelasticity (where both λω and λγ 0 exceed unity), and (iii) linear viscoelasticity (where λω exceeds unity and where λγ 0 approaches zero). We learn that the polymer orientation distribution is spherical in the linear viscoelastic regime, and otherwise tilted and peanut-shaped. We find that the peanut-shaping is mainly caused by the zeroth harmonic, and the tilting, by the second. The first, third, and fourth harmonics of the orientation distribution make only slight contributions to the overall polymer motion.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

TOUGH2-seed: A coupled fluid flow and mechanical-stochastic approach to model injection-induced seismicity

Understanding the injection-induced triggering mechanism is a fundamental step towards controlling the seismicity generated by deep underground exploitation. Here we propose a modeling approach based on coupling the TOUGH2 simulator with a geomechanical-stochastic model. Additionally, the hydro-mechanical-stochastic model provides a good representation of different mechanisms influencing each other during and after the injection phase. Each mechanism affects the induced seismicity in a different way and at different times during the reservoir stimulation, confirming that a complex interaction is in place, and that more sophisticated and physics-based approaches coupled with statistical model are required to explain such a complex interaction. In addition to previous statistical and hybrid models, our approach accounts for a full 3D formulation of both stresses and fluid flow, further including all the TOUGH2 capabilities. Furthermore, it includes interactions between triggered seismic events through calculation of static stress transfer. Here, in this work, we present the main capabilities of TOUGH2-SEED and apply the model to the Basel EGS case, successfully reproducing the injection pressure as well as the evolution of the seismicity.

58 GEOSCIENCES↗
DOE OSTI2016

A residual stress study in similar and dissimilar welds

Residual strain distributions in similar and dissimilar welds were measured using neutron diffraction (ND) method. Then, using three strain components, three-dimensional stress states were calculated. The results were used to determine the effect of the martensitic phase transformation and material properties on residual stress (RS) distribution. It was observed that smaller longitudinal RS was induced in the low carbon steel side of dissimilar weld when compared to its similar weld. Also, it was found that the transverse RS near and within the weld zone (WZ) in dissimilar weld exhibited a distinctive trend, with tensile mode reaching the yield strength of the base metal (BM). In order to characterize the WZ in dissimilar weld, we deployed optical microscopy, hardness, and energy dispersive X-ray spectroscopy (EDAX). This study not only provides further insight into the RS state in similar and dissimilar welds; it also delivers important consequences of phase transformation in the latter case.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Influences of granular constraints and surface effects on the heterogeneity of elastic, superelastic, and plastic responses of polycrystalline shape memory alloys

Deformation heterogeneities at the microstructural length-scale developed in polycrystalline shape memory alloys (SMAs) during superelastic loading are studied using both experiments and simulations. In situ X-ray diffraction, specifically the far-field high energy diffraction microscopy (ff-HEDM) technique, was used to non-destructively measure the grain-averaged statistics of position, crystal orientation, elastic strain tensor, and volume for hundreds of austenite grains in a superelastically loaded nickel-titanium (NiTi) SMA. These experimental data were also used to create a synthetic microstructure within a finite element model. The development of intragranular stresses were then simulated during tensile loading of the model using anisotropic elasticity. Driving forces for phase transformation and slip were calculated from these stresses. The grain-average responses of individual austenite crystals examined before and after multiple stress-induced transformation events showed that grains in the specimen interior carry more axial stress than the surface grains as the superelastic response "shakes down". Examination of the heterogeneity within individual grains showed that regions near grain boundaries exhibit larger stress variation compared to the grain interiors. As a result, this intragranular heterogeneity is more strongly driven by the constraints of neighboring grains than the initial stress state and orientation of the individual grains.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Simple effective conservative treatment of uncertainty from sparse samples of random functions

This paper examines the variability of predicted responses when multiple stress-strain curves (reflecting variability from replicate material tests) are propagated through a finite element model of a ductile steel can being slowly crushed. Over 140 response quantities of interest (including displacements, stresses, strains, and calculated measures of material damage) are tracked in the simulations. Each response quantity’s behavior varies according to the particular stress-strain curves used for the materials in the model. We desire to estimate response variability when only a few stress-strain curve samples are available from material testing. Propagation of just a few samples will usually result in significantly underestimated response uncertainty relative to propagation of a much larger population that adequately samples the presiding random-function source. A simple classical statistical method, Tolerance Intervals, is tested for effectively treating sparse stress-strain curve data. The method is found to perform well on the highly nonlinear input-to-output response mappings and non-standard response distributions in the can-crush problem. The results and discussion in this paper support a proposition that the method will apply similarly well for other sparsely sampled random variable or function data, whether from experiments or models. Finally, the simple Tolerance Interval method is also demonstrated to be very economical.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Novel silicon allotropes: Stability, mechanical, and electronic properties

One quasi-direct gap phase (Amm2) and three indirect gap phases (C2/m-16, C2/m-20, and I-4) of silicon allotropes are proposed. The detailed theoretical study on the structure, density of states, elastic properties, sound velocities, and Debye temperature of these four phases is carried out by using first principles calculations. The elastic constants of these four phases are calculated by strain-stress method. The elastic constants and the phonon calculations manifest all novel silicon allotropes in this paper are mechanically and dynamically stable at ambient condition. The B/G values indicate that these four phases of silicon are brittle materials at ambient pressure. The anisotropy properties show that C2/m-20 phase exhibits a larger anisotropy in its elastic modulus, shear elastic anisotropic factors, and several anisotropic indices than others. We have found that the Debye temperature of the four novel silicon allotropes gradually reduces in the order of C2/m-20 > Amm2 > C2/m-16 > I-4 at ambient pressure.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Variant selection in laser powder bed fusion of non-spherical Ti-6Al-4V powder

The presence of α/α' on prior β/β grain boundaries directly impacts the final mechanical properties of the titanium alloys. The β/β grain boundary variant selection of titanium alloys has been assumed to be unlikely owing to the high cooling rates in laser powder bed fusion (L-PBF). However, we hypothesize that powder characteristics such as morphology (non-spherical) and particle size (50–120 µm) could affect the initial variant selection in L-PBF processed Ti-6Al-4V alloy by locally altering the cooling rates. Despite the high cooling rate found in L-PBF, the results showed the presence of β/β grain boundary α' lath growth inside two adjacent prior β grains. Electron backscatter diffraction micrographs confirmed the presence of β/β grain boundary variant selection, and synchrotron X-ray high-speed imaging observation revealed the role of the “shadowing effect” on the locally decreased cooling rate because of keyhole depth reduction and the consequent β/β grain boundary α' lath growth. The self-accommodation mechanism was the main variant selection driving force, and the most abundant α/α boundary variant was type 4 (63.26°//[ $\bar{10}$ 5 5 $\bar{3}$ ]). The dominance of Category II α lath clusters associated with the type 4 α/α boundary variant was validated using the phenomenological theory of martensite transformations and analytical calculations, from which the stress needed for the β→α' transformation was calculated.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effects of thermal cycling parameters on residual stresses in alumina scales of CoNiCrAlY and NiCoCrAlY bond coats

In this paper, furnace cycling experiments were performed on free-standing high-velocity oxygen-fuel bond coat samples to investigate the effect of material composition, surface texture, and cycling conditions on the average stresses in the formed oxide scales after cooling. The oxide scale thicknesses were determined by SEM image analyses and information about the stresses were acquired by photo-stimulated luminescence-spectroscopy. Additionally, the scale thickness dependent stress fields were calculated in finite-element analyses including approximation functions for the surface roughness derived on the basis of profilometry data. The evolution of the average residual stress as a function of oxide scale thickness was subject to stochastic fluctuations predominantly caused by local scale spallations. In comparison to the supplemental modeling results, thermal stresses due to mismatch of thermal expansion coefficients are identified as the main contribution to the residual stresses. Finally, the theoretical results emphasize that analyses of spectroscopic data acquired for average stress investigations of alumina scales rely on detailed information about microstructural features.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Reduced model for direct induction startup scenario development on MAST-U and NSTX-U

A reduced semi-empirical model using time-dependent axisymmetric vacuum field calculations is used to develop the prefill and feed-forward coil current targets required for reliable direct induction (DI) startup on the new MA-class spherical tokamaks, MAST-U and NSTX-U. The calculations are constrained by operational limits unique to each device, such as the geometry of the conductive elements and active coils, power supply specifications and coil heating and stress limits. The calculations are also constrained by semi-empirical models for sufficient breakdown, current drive, equilibrium and stability of the plasma developed from a shared database. A large database of DI startup on NSTX and NSTX-U is leveraged to quantify the requirements for achieving a reliable breakdown (I p ~ 20 kA). It is observed that without pre-ionization, STs access the large E/P regime at modest loop voltage (V loop ) where the electrons in the weakly ionized plasma are continually accelerating along the open field lines. This ensures a rapid (order millisecond) breakdown of the neutral gas, even without pre-ionization or high-quality field nulls. The timescale of the initial increase in I p on NSTX is reproduced in the reduced model provided a mechanism for impeding the applied electric field is included. Most discharges that fail in the startup phase are due to an inconsistency in the evolution of the plasma current (I p ) and equilibrium field or loss of vertical stability during the burn-through phase. Here, the requirements for the self-consistent evolution of the fields in the weakly and fully-ionized plasma states are derived from demonstrated DI startup on NSTX, NSTX-U and MAST. The predictive calculations completed for MAST-U and NSTX-U illustrate that the maximum I p ramp rate (dI p /dt) in the early startup phase is limited by the voltage limits on the poloidal field coils on MAST-U and passive vertical stability on NSTX-U.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Reduced Model for Direct Induction Startup Scenario Development on MAST-U and NSTX-U

A reduced semi-empirical model using time-dependent axisymmetric vacuum field calculations is used to develop the prefill and feed-forward coil current targets required for reliable direct induction (DI) startup on the new MA-class spherical tokamaks, MAST-U and NSTX-U. The calculations are constrained by operational limits unique to each device, such as the geometry of the conductive elements and active coils, power supply specifications and coil heating and stress limits. The calculations are also constrained by semi-empirical models for sufficient breakdown, current drive, equilibrium and stability of the plasma developed from a shared database. A large database of DI startup on NSTX and NSTX-U is leveraged to quantify the requirements for achieving a reliable breakdown (Ip ~ 20 kA). It is observed that without pre-ionization, STs access the large E/P regime at modest loop voltage (Vloop) where the electrons in the weakly ionized plasma are continually accelerating along the open field lines. This ensures a rapid (order millisecond) breakdown of the neutral gas, even without pre-ionization or high-quality field nulls. The timescale of the initial increase in Ip on NSTX is reproduced in the reduced model provided a mechanism for impeding the applied electric field is included. Most discharges that fail in the startup phase are due to an inconsistency in the evolution of the plasma current (Ip) and equilibrium field or loss of vertical stability during the burn-through phase. The requirements for the self-consistent evolution of the fields in the weakly and full-ionized plasma states are derived from demonstrated DI startup on NSTX, NSTX-U and MAST. The predictive calculations completed for MAST-U and NSTX-U illustrate that the maximum Ip ramp rate (dIp/dt) in the early startup phase is limited by the voltage limits on the poloidal field coils on MAST-U and passive vertical stability on NSTX-U.

Direct induction↗
DOE OSTI2023

Using in-situ strain measurements to evaluate the accuracy of stress estimation procedures from fracture injection/shut-in tests

Fracture injection/shut-in tests are commonly used to measure the state of stress. Injection creates a hydraulic fracture (or in some cases, opens a preexisting fracture), and then the pressure after shut-in is monitored to identify fracture closure. Different interpretation procedures have been proposed for estimating closure, and the procedures sometimes yield significantly different results. In this study, direct, in-situ strain measurements are used to observe fracture reopening and closure. The tests were performed as part of the EGS Collab project, a mesoscale project performed at 1.25 and 1.5 km depth at the Sanford Underground Research Facility. The tests were instrumented with the SIMFIP tool, a double-packer probe with a high-resolution three-dimensional borehole displacement sensor. The measurements provide a direct observation of the fracture closure signature, enabling a high-fidelity estimate of the fracture closure stress (ie, the normal stress on the fracture). In two of the four tests, injection created an opening mode fracture, and so the closure stress can be interpreted as the minimum principal stress. In the other two tests, injection probably opened preexisting natural fractures, and so the closure stress can be interpreted as the normal stress on the fractures. The strain measurements are compared against different proposed methods for estimating closure stress from pressure transients. The shut-in transients are analyzed with two techniques that are widely used in the field of petroleum engineering – the ‘tangent’ method and the ‘compliance’ method. In three of the four tests, the tangent method significantly underestimates the closure stress. The compliance method is reasonably accurate in all four tests. Closure stress is also interpreted using two other commonly-used methods – ‘first deviation from linearity’ and the method of Hayashi and Haimson. In comparison with the SIMFIP data, these methods tend to overestimate the closure stress, evidently because they identify closure from early-time transient effects, such as near-wellbore tortuosity. In two of the tests, microseismic imaging provides an independent estimate of the size of the fracture created by injection. When combined with a simple mass balance calculation, the SIMFIP stress measurements yield predictions of fracture size that are reasonably consistent with the estimates from microseismic. In conclusion, the calculations imply an apparent fracture toughness 2-3x higher than typical laboratory-derived values.

58 GEOSCIENCES↗
DOE OSTI2019

Evaluation of a thermomechanical model for prediction of residual stress during laser powder bed fusion of Ti-6Al-4V

The build-up of residual stresses in a part during laser powder bed fusion provides a significant limitation to the adoption of this process. These residuals stresses may cause a part to fail during a build or fall outside the specified tolerances after fabrication. In the present work a thermomechanical model is used to simulate the build process and calculate the residual stress state for Ti–6Al–4V specimens built with continuous and island scan strategies. A layer agglomeration, or lumping, approach is used to speed up the computations. A material model is developed to naturally capture the strain-rate dependence and annealing behavior of Ti–6Al–4V at elevated temperatures. Conclusions from the thermomechanical simulations showed good agreement with synchrotron X-ray diffraction measurements used to determine the residual elastic strains in these parts. Yet, the experimental measurements showed higher residual strains for the specimen built with an island scan strategy; a trend not fully captured by the simulations. Parameter studies were performed to fully understand the advantages and limitations of the current simulation methodology. Reasons for both the computational and experimental findings are discussed.

36 MATERIALS SCIENCE↗