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At least 199 records · Page 11

Stress Relaxation Related to Spontaneous Thin Film Buckling: Correlation between Finite Element Calculations and Micro Diffraction Analysis

Compressive residual stresses generated during thin film deposition may lead to undesirable film damage, such as delamination, buckling, and flaking, ultimately leading to the failure of the device employing the film. Understanding the residual stress generation and role in these damage mechanisms is necessary to preserve thin film integrity and optimize its functional properties. Thin shell theory has been used for decades to predict buckling but the results have not yet been correlated with experimental data since the techniques used to measure stress in metallic films were not able to do so at the required micron scale until recently. Micro scanning X-ray diffraction now enables the direct mapping of the local stress of metallic films. In this paper, finite element method based on thin shell theory and synchrotron X-ray micro diffraction have been used to determine stress maps of thin film buckling patterns. Calculations of the stress distribution in the metallic films have been performed taking into account the buckling geometry determined from optical measurements. Stress distributions over gold blisters and tungsten wrinkles obtained with the two techniques are in fair agreement and allow for the accurate determination of the stress relaxation profile from the bottom to the top of the buckling, validating the thin shell theory model.

36 MATERIALS SCIENCE↗

Anisotropic elastoplastic response of double-porosity media

Here we present a continuum framework to simulate fluid flow through anisotropic elastoplastic media with double porosity. Two effective stress measures σ' and δ" emerge from the thermodynamic formulation, which are energy-conjugate to the elastic and plastic components of strain, respectively. Both effective stress measures can be expressed as a combination of the total Cauchy stress σ and the average pore pressure $\bar{p}$ in the two pore scales. In the effective stress for elasticity, $\bar{p}$ is scaled with a rank-2 Biot tensor, whereas the effective stress for plasticity follows the Terzaghi form in which $\bar{p}$ is scaled by the Kronecker delta. The Biot tensor and storage coefficients are derived as functions of elasticity parameters and porosities. A mixed finite element formulation is introduced to discretize the domain and solve initial boundary-value problems. A stabilization scheme is employed on equal-order interpolation for both displacement and pressure fields throughout the entire range of drainage responses. Numerical simulations reproduce the hydromechanical response of Opalinus shale in one-dimensional consolidation tests throughout the range of primary and secondary consolidation under different external loads. Numerical simulations of the consolidation of a rectangular domain subjected to a strip load demonstrate the efficacy of the proposed stabilization scheme, as well as illustrate the impacts of stress history, mass transfer, and different pore systems on the hydromechanical response.

42 ENGINEERING↗

Correlation Between Irradiation Defects and Transition Dimension for TEM In Situ Mechanical Testing

The objective of this study is to establish a relationship between specimen size effect transition dimension and defect number density. Transmission electron microscopic (TEM) in situ mechanical testing enables one to directly observe fundamental plastic phenomena simultaneous to quantitative measurement of applied load and displacement, in specimens having dimensions on the order of nanometers to micrometers. Thus, these techniques hold great promise for enhancing our scientific understanding of deformation mechanisms in volume-limited materials, such as shallow ion irradiated layers. The 'specimen size effect' is a major detractor, however, of any miniaturized mechanical testing technique. This effect is the direct result of low-volume specimens containing too few dislocations, such that plasticity is governed by the stress required to introduce more dislocations to the specimen. The consequence is an inflated yield stress measurement relative to the 'bulk' yield stress. As the specimen size increases, so too does the number of dislocations present, and plasticity becomes controlled by the stress needed to move these dislocations. Yield stress measurements decrease to their bulk values. The minimum specimen dimension for which plastic yield is controlled by dislocation motion rather than dislocation introduction, is what we herein refer to as the 'transition dimension'. However, the overall yield stress is governed by the superposition of dislocations, grain boundaries, and dispersed obstacles of varying morphologies. It is theorized that the higher the number density of these dispersed obstacles, the lower the transition dimension. Since it is well known that irradiation introduces a high density of defects, we hypothesize that the transition dimension is sufficiently low in irradiated materials so as to enable meaningful quantitative values of yield stress through TEM in situ mechanical tests.

36 MATERIALS SCIENCE↗

Axisymmetric and Focusing Analyzers to Enable Efficient Powder and Residual Stress Neutron Diffractometers

Project Summary: Company: Adelphi Technology, Inc., Redwood City, CA 94063-4121 DOE Phase 1 STTR PI: Dr. Jay Theodore Cremer, Jr. Chief Scientist at Adelphi Technology, Inc. DOE Phase 1 STTR with: Dr. Boris Khaykovich of Massachusetts Institute of Technology (MIT) MIT Nuclear Reactor Laboratory DOE Phase 1 STTR Title: Axisymmetric and Focusing Analyzers to Enable Efficient Powder and Residual Stress Neutron Diffractometers 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, so as 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 strive to achieve the goal of efficient use of available thermal and cold neutrons, by introducing here, novel analyzers for powder diffraction and stress-strain measurements. These analyzers will enable polychromatic cold and thermal neutron diffractometers, which will have much higher throughput than existing instruments. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast instruments for screening of multiple samples, for measuring kinetic processes, or for measuring residual stress tensors. Commercial Applications and Other Benefits: By combining the novel analyzers with the Adelphi thermal neutron generator, we will open a new market, which includes the testing of samples that cannot be transported, such as nuclear fuels, or the testing of parts during production. Given the reasonable cost and size of our proposed analyzer systems, along with the continuing development of more powerful thermal neutron generators, the proposed analyzers will be suitable for weak neutrons sources, which are installed at small to large university, industrial, and government laboratories. Key Words: Neutron powder diffraction, residual stress measurements, thermal neutron generators, TRIGA reactors, low flux thermal and cold neutron sources, neutron diffraction. 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 ↗

Development of Predictive Model for Accurate Rupture Time from Multi-Axial Creep in Alloy 709 with Physics-Based Simulations

A physics-based model is developed to predict multiaxial creep behavior in Alloy 709 (A709), an advanced austenitic stainless steel intended for high-temperature applications such as Sodium Fast Reactors (SFRs). Compared to conventional stainless steels like 316H, A709 offers superior high-temperature performance; however, comprehensive data on its multiaxial creep response remain limited. To address this gap, a crystal plasticity finite element (CPFE) framework is used to simulate the deformation and failure mechanisms of A709 under multiaxial loading conditions. The model incorporates an extended Hu-Cocks dislocation creep formulation that accounts for precipitation effects, along with the Sham–Needleman model to capture grain boundary cavitation-driven failure. These advanced constitutive models enable a detailed understanding of the interplay between microstructural evolution and macroscopic creep response. Furthermore, the study evaluates the predictive accuracy of various effective stress measures in estimating creep rupture life, leveraging simulated multiaxial creep data. The findings provide critical insights into the applicability of different stress measures for engineering design and life prediction of A709 components operating under complex loading conditions. This work contributes to improving the reliability of high-temperature structural components by advancing predictive modeling capabilities for advanced austenitic steels.

Alloy 709↗

Use of Cosserat birefringence to measurement couple stresses by photoelasticity

The quantum analysis of the polar atom under the action of a mechanical load is presented in this work. The obtained solution can be used to describe the optical properties of the Cosserat medium in the form of the gyro-birefringence. Rayleigh scattering of laser light coming towards the Cosserat medium head is analysed to measure the rotation of the azimuth of polarisation associated with couple stresses.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

A kinetic model for stress generation in thin films grown from energetic vapor fluxes

We have developed a kinetic model for residual stress generation in thin films grown from energetic vapor fluxes, encountered, e.g., during sputter deposition. The new analytical model considers sub-surface point defects created by atomic peening, along with processes treated in already existing stress models for non-energetic deposition, i.e., thermally activated diffusion processes at the surface and the grain boundary. According to the new model, ballistically induced sub-surface defects can get incorporated as excess atoms at the grain boundary, remain trapped in the bulk, or annihilate at the free surface, resulting in a complex dependence of the steady-state stress on the grain size, the growth rate, as well as the energetics of the incoming particle flux. We compare calculations from the model with in situ stress measurements performed on a series of Mo films sputter-deposited at different conditions and having different grain sizes. The model is able to reproduce the observed increase of compressive stress with increasing growth rate, behavior that is the opposite of what is typically seen under non-energetic growth conditions. On a grander scale, this study is a step towards obtaining a comprehensive understanding of stress generation and evolution in vapor deposited polycrystalline thin films.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Electromechanical Apparatus Measures Residual Stress

Nondestructive test exploits relationship between stress and eddy-current-probe resistance. Yields data on residual stress or strain in metal tension/compression specimen (stress or strain remaining in specimen when no stress applied from without). Apparatus is assembly of commercial equipment: tension-or-compression testing machine, eddy-current probe, impedance gain-and-phase analyzer measuring impedance of probe coil, and desktop computer, which controls other equipment and processes data received from impedance gain-and-phase analyzer.

Chern, Engmin J.↗

Modifications of system for elevated temperature tensile testing and stress-strain measurement of metal matrix composites

Composites consisting of tungsten alloy wires in superalloy matrices are being studied because they offer the potential for increased strength compared to current materials used at temperatures up to at least 1093 C (2000F). Previous research at the NASA Lewis Research Center and at other laboratories in the U.S., Europe, and Japan has demonstrated laboratory feasibility for fiber reinforced superalloys (FRS). The data for the mechanical and physical properties used to evaluate candidate materials is limited and a need exists for a more detailed and complete data base. The focus of this work is to develop a test procedure to provide a more complete FRS data base to quantitatively evaluate the composite's potential for component applications. This paper will describe and discuss the equipment and procedures under development to obtain elevated temperature tensile stress-strain, strength and modulus data for the first generation of tungsten fiber reinforced superalloy composite (TFRS) materials. Tensile stress-strain tests are conducted using a constant crosshead speed tensile testing machine and a modified load-strain measuring apparatus. Elevated temperature tensile tests are performed using a resistance wound commercial furnace capable of heating test specimens up to 1093 C (2000 F). Tensile stress-strain data are obtained for hollow tubular stainless steel specimens serving as a prototype for future composite specimens.

Diaz, J. O.↗

Intrinsic momentum generation by a combined neoclassical and turbulence mechanism in diverted DIII-D plasma edge

Fluid Reynolds stress from turbulence has usually been considered to be responsible for the anomalous toroidal momentum transport in tokamak plasma. Experiment by Müller et al. [Phys. Rev. Lett. 106, 115001 (2011)], however, reported that neither the observed edge rotation profile nor the inward momentum transport phenomenon at the edge region of an H-mode plasma could be explained by the fluid Reynolds stress measured with reciprocating Langmuir-probe. The full-function gyrokinetic code XGC1 is used to explain, for the first time, Müller et al.'s experimental observations. It is discovered that, unlike in the plasma core, the fluid Reynolds stress from turbulence is not sufficient for momentum transport physics in plasma edge. The “turbulent neoclassical” physics arising from the interaction between kinetic neoclassical orbit dynamics and plasma turbulence is key in the tokamak edge region across the plasma pedestal into core.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

In Situ Measurement of Stress Corrosion Crack Tip Properties During Environmentally Induced Cracking in Stainless Steel 304L

The influence of the external cathodic area, stress intensity, and electrochemical polarization level on the resultant crack growth rate and crack tip pH and potential was studied for stainless steel 304L in a sodium chloride environment. Before testing, the validity of in situ crack tip property measurements using microprobes and drilled holes was supported through modeling efforts and confirmed with experimental observations. Here, it was found that increasing the R-ratio during corrosion fatigue increased the crack growth rate and decreased the measured crack tip pH of the 304L sample. Decreasing the electrochemical potential (i.e., cathodic polarization) of the bulk sample increased the crack tip pH and stopped measured crack extension under constant K conditions. Conversely, increasing the potential of the bulk sample decreased the crack tip pH and induced cracking under constant K conditions. Decreasing the cathodic area external to the crack increased the measured pH at the crack tip and decreased the crack growth rate under fatigue conditions. For the given configuration, environment, and alloy studied, fatigue crack growth is not sustained by cathodic reactions solely occurring in the crack wake and notch. These results have implications for the ability to predict atmospheric crack growth rates from laboratory, full immersion experiments.

corrosion fatigue↗

Life Prediction of Spent Fuel Storage Canister Material

The original purpose of this project was to develop a probabilistic model for SCC-induced failure of spent fuel storage canisters, exposed to a salt-air environment in the temperature range 30-70°C for periods up to and exceeding 100 years. The nature of this degradation process, which involves multiple degradation mechanisms, combined with variable and uncertain environmental conditions dictates a probabilistic approach to life prediction. A final report for the original portion of the project was submitted earlier. However, residual stress measurements for as-welded and repair welds could not be performed within the original time of the project. As a result of this, a no-cost extension was granted in order to complete these tests. In this report, we report on the results of residual stress measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Obtaining spectral reflectance factor measurements of stressed forest vegetation

Techniques and instruments used to collect spectral reflectance data on Vermont spruce and fir stands subjected to stress (due to acid rain and ozone) are described and illustrated. The healthy and stressed sites selected are characterized; the data-quality requirements are indicated; and particular attention is given to (1) a helicopter-mounted instrument package (radiometer, spectrometer, cameras, and video camera) for canopy-level remote sensing of reflectance and (2) a portable hemispherical light source for use in taking laboratory reflectance measurements from branches or needles. Typical data are presented in graphs and briefly discussed.

Case, David W.↗

It's the Heat AND the Humidity -- Assessment of Extreme Heat Scenarios to Enable the Assessment of Climate Impacts on Public Health

In the United States, extreme heat is the most deadly weather-related hazard. In the face of a warming climate and urbanization, which contributes to local-scale urban heat islands, it is very likely that extreme heat events (EHEs) will become more common and more severe in the U.S. In a NASA-funded project supporting the National Climate Assessment, we are providing historical and future measures of extreme heat to enable assessments of the impacts of heat on public health over the coterminous U.S. We use atmospheric temperature and humidity information from meteorological reanalysis and from Global Climate Models (GCMs) to provide data on past and future heat events. The project s emphasis is on providing assessments of the magnitude, frequency and geographic distribution of extreme heat in the U.S. to facilitate public health studies. In our approach, long-term climate change is captured with GCM output, and the temporal and spatial characteristics of short-term extremes are represented by the reanalysis data. Two future time horizons, 2040 and 2090, are the focus of future assessments; these are compared to the recent past period of 1981-2000. We are characterizing regional-scale temperature and humidity conditions using GCM output for two climate change scenarios (A2 and A1B) defined in the Special Report on Emissions Scenarios (SRES). For each future period, 20 years of multi-model GCM output have been analyzed to develop a heat stress climatology based on statistics of extreme heat indicators. Differences between the two future and past periods have been used to define temperature and humidity changes on a monthly time scale and regional spatial scale. These changes, combined with hourly historical meteorological data at a spatial scale (12 km) much finer than that of GCMs, enable us to create future climate realizations, from which we compute the daily heat stress measures and related spatially-specific climatological fields. These include the mean annual number of days above certain thresholds of maximum and minimum air temperatures, heat indices and a new heat stress variable that gives an integrated measure of heat stress (and relief) over the course of a day. Comparisons are made between projected (2040 and 2090) and past (1990) heat stress statistics. All output is being provided at the 12 km spatial scale and will also be aggregated to the county level, which is a popular scale of analysis for public health researchers. County-level statistics will be made available by our collaborators at the Centers for Disease Control and Prevention (CDC) via the Wide-ranging Online Data for Epidemiologic Research (WONDER) system. CDC WONDER makes the information resources of the CDC available to public health professionals and the general public. This addition of heat stress measures to CDC WONDER will allow decision and policy makers to assess the impact of alternative approaches to optimize the public health response to EHEs. It will also allow public health researchers and policy makers to better include such heat stress measures in the context of national health data available in the CDC WONDER system. The users will be able to spatially and temporally query public health and heat-related data sets and create county-level maps and statistical charts of such data across the coterminous U.S.

Crosson, William L↗

Effect of shot peening on surface fatigue life of carburized and hardened AISI 9310 spur gears

Surface fatigue tests were conducted on two groups of AISI 9310 spur gears. Both groups were manufactured with standard ground tooth surfaces, with the second group subjected to an additional shot peening process on the gear tooth flanks. The gear pitch diameter was 8.89 cm (3.5 in.). Test conditions were a gear temperature of 350 K (170 F), a maximum Hertz stress of 1.71 billion N/sq m (248,000 psi), and a speed of 10,000 rpm. The shot peened gears exhibited pitting fatigue lives 1.6 times the life of standard gears without shot peening. Residual stress measurements and analysis indicate that the longer fatigue life is the result of the higher compressive stress produced by the shot peening. The life for the shot peened gear was calculated to be 1.5 times that for the plain gear by using the measured residual stress difference for the standard and shot peened gears. The measured residual stress for the shot peened gears was much higher than that for the standard gears.

Townsend, D. P.↗

Inelastic Deformation in Methylammonium Lead Iodide Perovskite and Mitigation by Additives during Thermal Cycling

Metal halide perovskite thin films are promising materials for next-generation photovoltaic applications, but the thermomechanical instabilities of these materials are critical barriers to device longevity. In this study, we measure the evolution of stresses in methylammonium lead iodide (MAPbI3) films thermally cycled from 25 to 105 °C using a multibeam optical stress sensor (MOSS) system. We demonstrate that these films undergo residual stress buildup due to inelastic deformation as well as a simple mitigation strategy by incorporating low concentrations of 5-aminovaleric acid hydrochloride (5-AVACl) as an additive. Adding 5-AVACl increases the tensile stresses measured at room temperature but beneficially decreases the biaxial modulus from 9.60 ± 0.44 GPa to 7.95 ± 0.55 GPa, resulting in greater accommodation of thermal stresses. The hysteresis loop is ~63% smaller with the inclusion of 5-AVACl, and the stress relaxation at 50 °C decreases from 86.46 to 51.49 MPa. The larger stress relaxation in pristine MAPbI 3 is correlated with grain boundary opening after five cycles, while the inclusion of 5-AVACl mitigates this degradation. Furthermore, our findings underscore the importance of studying the dynamic response of perovskite films during thermal cycling and lay the foundation for further exploration into the mechanisms governing the thermomechanical behavior of perovskite thin films.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Measuring the Stress Factors for Photovoltaic (PV) Backsheet Degradation

Back sheet failure has resulted in power loss and large-scale recall of photovoltaic modules, resulting in billions of dollars in lost revenue. The light exposure on the backside of a photovoltaic module comes primarily from reflected light which alters the distribution of natural sunlight. Because of this, modelling the backside exposure and duplicating the exposure is much more difficult than modeling the frontside exposure. This project aims to study how various back sheets and junction box materials degrade under different conditions and to develop Python code to help model and predict degradation. The stress factors for back-sheet degradation must be quantified to extrapolate accelerated stress tests to the field. Test samples were placed in the A3, A4, and A5 conditions, as defined in IEC 62788-7-2, to assess the temperature and humidity dependence of ultraviolet (UV) induced degradation. We are utilizing a custom chamber with exposure from 0.5 UV-suns to 5 UV-suns to understand the dependence of degradation on light intensity. A group of samples put in the A3 condition had glass filters with 50% UV cut-offs of 320 nm, 335 nm, and 360 nm to assess the wavelength dependence of UV degradation. All this data is necessary to assess the impact of non-standard UV light exposure. The material evaluation tests include gloss measurements, attenuated total internal reflectance Fourier transform infrared spectroscopy (ATR-FTIR), UV-visible reflectance/transmittance utilizing a Cary Ci7000 spectrophotometer, and a nano-indenter for surface hardness and modulus measurements. Alongside the experimental work, there is a computational effort using raytracing and Python open-source tools in PVDeg , PVLib, and Bifacial_Radiance. This code will create specific exposure scenarios and enable the evaluation of chamber degradation relative to field degradation. Equation 1 is a strawman equation used to model degradation on the backside of a PV module. We will create simplified code, based on the results of ray-tracing calculations, which uses a view factor approach to provide fast calculations for the most common exposure scenarios.

14 SOLAR ENERGY↗