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At least 217 records · Page 12

All sources NASA NTRS DOE OSTI

DOE OSTI2016

Validation of a cyclic plasticity computational method using fatigue full-field deformation measurements

The evolution of crack tip displacement and strain fields during uniaxial, room temperature, low-cycle fatigue experiments of Nickel superalloy compact tension specimens was measured by a digital image correlation approach and was further used to validate a cyclic plasticity model and corresponding deformation calculations made by a finite elements methodology. The experimental results provided data trends for the opening displacements and near crack tip strains as function of cycles. A finite element model was developed to capture test conditions for a measured crack size. The model captures crack tip plasticity by using a constitutive model calibrated against stress-strain measurements performed on a round bar. Similar quantities were extracted from the model predictions to compare with the digital image correlation measurements for model validation purposes. This type of direct comparison demonstrated that the computational model was capable to adequately capture the crack opening displacements at various stages of the specimen's fatigue life, providing in this way a tool for quantitative cyclic plasticity model validation. In addition, this integrated experimental-computational approach provides a framework to accelerate our understanding related to interactions of fatigue test data and models, as well as ways to inform one another.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Elucidating Cycling Rate-Dependent Electrochemical Strains in Sodium Iron Phosphate Cathodes for Na-ion Batteries

Battery electrodes materials undergo significant mechanical instabilities which affects their longevity and exert rate-limitations during the cycling process. In this study, we investigate the rate-dependent mechanical response of sodium iron phosphate (NaFePO4, NFP) cathodes during Na intercalation via galvanostatic cycling at different rates by employing digital image correlation, electrochemical methods, and mathematical model. The mechanical behaviour of the electrode shows strong dependance on the applied scan rate. At slower rates, electrode shows asymmetrical strain generation between anodic and cathodic cycles, which is attributed to the formation of cathode-electrolyte interface layers. The electrode undergoes smaller strain generation when cycled at slower rates when the same amount of Na ions is removed or inserted into the electrode. A mathematical model was developed to predict strain evolution in the composite electrode as well as the concentration profile of the Na ions in the electrode particles. Rate-dependent and time dependent factors on the strain generation in the electrode are attributed to the capacity-dependent intercalation strains, rate-dependent mismatch strains, and time-dependent irreversible strains. The combination of in situ strain measurements with the analytical model provided new insight into the electrochemically induced mechanical deformations in Na-ion cathode electrodes.

Ozdogru, Bertan↗

NASA NTRS2008

Full-field Strain Methods for Investigating Failure Mechanisms in Triaxial Braided Composites

Composite materials made with triaxial braid architecture and large tow size carbon fibers are beginning to be used in many applications, including composite aircraft and engine structures. Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape. Although the large unit cell size of these materials is an advantage for manufacturing efficiency, the fiber architecture presents some challenges for materials characterization, design, and analysis. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A potential problem with using standard tests methods for these materials is that the unit cell size can be an unacceptably large fraction of the specimen dimensions. More detailed investigation of deformation and failure processes in large unit cell size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. In recent years, commercial equipment has become available that enables digital image correlation to be used on a more routine basis for investigation of full field 3D deformation in materials and structures. In this paper, some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques are presented. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12 and 24 k yarns and a 0/+60/-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed, and this local failure had a significant effect on global stiffness and strength. The matrix material had a large effect on local damage initiation for the two matrix materials used in this investigation. Premature failure in regions of the unit cell near the edge of the straight-sided specimens was observed for transverse tensile tests in which the braid axial fibers were perpendicular to the specimen axis and the bias fibers terminated on the cut edges in the specimen gage section. This edge effect is one factor that could contribute to a measured strength that is lower than the actual material strength in a structure without edge effects.

Littell, Justin D.↗

DOE OSTI2018

Enabling high resolution strain mapping in zirconium alloys

Highlights: • Optimisation of speckle patterns suitable for high resolution digital image correlation in a zirconium alloy • Evidence of distinct strain patterning at the macro and micro scale • Analysis of strain heterogeneity in a neighbouring low and high strain band • Paved the way for future studies on strain localization in zirconium alloys subjected to hydriding and irradiation damage - Abstract: High Resolution Digital Image Correlation (HRDIC) has been established recently as a novel displacement mapping technique during mechanical loading experiments to quantify strain localisation down to the level of individual slip traces. This is achieved by the creation of a nano-scale gold pattern naturally formed during remodelling of a thin gold layer that was sputtered onto the region of interest. To date, the gold remodelling is carried out in a water vapourisation environment, which excludes the technique to be applied to materials that readily form noticeable oxide layers in such environments. The current paper describes a recently developed gold remodelling technique using a styrene-argon environment at substantially lower temperatures than the water-vapour based technique. The material used in the present work is a zirconium alloy where we first demonstrate the problem of oxide formation during remodelling in water vapour and the benefit of the modified remodelling procedure. The error associated with the spatial drift was assessed for different interrogation window sizes followed by detailed analysis of the subsequent strain maps produced using the styrene remodelled patterns after tensile deformation to nominal applied strains of ~3.5% and ~7.0%. The level of detail captured demonstrate the suitability of styrene-argon-based remodelling for materials like Zr alloys with the strain maps showing clear strain patterning on both a transgranular and single grain scale with the possibility of quantifying strain across a single slip trace.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Statistical Estimation of Strain Using Spatial Correlation Functions

Ex-situ estimation of strains from deformed micrographs is not possible as there are no persistent features which can be tracked. Two point spatial statistics enable the rigorous quantification of spatial patterns in heterogeneous media. In this paper, we propose a novel method for estimating strains directly from dissimilar micrographs using a continuum mechanics approach. Rather than operating directly on images from sequential frames, as is done in digital image correlation, we operate on different microstructure realizations. This is made possible by comparing the spatial autocorrelation maps of deformed and undeformed micrographs rather than direct comparison of images. Additionally, a Bayesian framework is proposed for quantifying uncertainty. We first illustrate the efficacy of this method on speckle pattern images from digital image correlation experiments. Then, we demonstrate that the method is capable of operating on dissimilar micrographs using deformed synthetic binary microstructures. Finally, we present a case study on polycrystalline additively manufactured 316L deformed via tension. The proposed method works well and we discuss implications and limitations of the presented work.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Resistance Curves in the Tensile and Compressive Longitudinal Failure of Composites

This paper presents a new methodology to measure the crack resistance curves associated with fiber-dominated failure modes in polymer-matrix composites. These crack resistance curves not only characterize the fracture toughness of the material, but are also the basis for the identification of the parameters of the softening laws used in the analytical and numerical simulation of fracture in composite materials. The method proposed is based on the identification of the crack tip location by the use of Digital Image Correlation and the calculation of the J-integral directly from the test data using a simple expression derived for cross-ply composite laminates. It is shown that the results obtained using the proposed methodology yield crack resistance curves similar to those obtained using FEM-based methods in compact tension carbon-epoxy specimens. However, it is also shown that the Digital Image Correlation based technique can be used to extract crack resistance curves in compact compression tests for which FEM-based techniques are inadequate.

Camanho, Pedro P.↗

DOE OSTI2018

Report on Design and Failure Limits of SiC/SiC and FeCrAl ATF Cladding Concepts under RIA

Pellet-cladding mechanical interaction (PCMI) is a possible failure scenario during a postulated reactivity-initiated accident (RIA). This report summarizes fiscal year 2018 research activities that were undertaken to evaluate the PCMI-like hoop strain–driven mechanical response of accident tolerant fuel cladding candidates of silicon carbide fiber/silicon carbide matrix composite (SiC/SiC) and iron–chromium–aluminum (FeCrAl) tube specimens. To achieve various RIA-like conditions, the modified-burst test device developed during fiscal years 2016 and 2017 was used. A heating capability was also added to the system for high-temperature testing of FeCrAl samples.The first section of this report assesses the accuracy of the two-dimensional digital image correlation calculated strain values for tube samples. The speckle patterns are computer generated in a two-dimensional plane, and the generated images were wrapped into a cylindrical surface for the validation using digital image correlation technique on curved geometries. Subsequent sections address the failure behavior of SiC/SiC composites and long-term heat treated and as-drawn FeCrAl alloy tubes at various strain rates relevant to the postulated RIA events. In the last part, the effect of possible design parameters of failure strain and the strain rate are discussed for SiC/SiC composites and FeCrAl alloys during the PCMI phase of RIA.Future work is planned to develop and design safety tests for accident tolerant fuel cladding candidates and the advanced fuel forms with respect to their transient responses. A broader perspective on the mechanical behavior of the unirradiated and irradiated accident tolerant fuel cladding candidates will be developed using the modified-burst test and other mechanical tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1992

Determination of high temperature strains using a PC based vision system

With the widespread availability of video digitizers and cheap personal computers, the use of computer vision as an experimental tool is becoming common place. These systems are being used to make a wide variety of measurements that range from simple surface characterization to velocity profiles. The Sub-Pixel Digital Image Correlation technique has been developed to measure full field displacement and gradients of the surface of an object subjected to a driving force. The technique has shown its utility by measuring the deformation and movement of objects that range from simple translation to fluid velocity profiles to crack tip deformation of solid rocket fuel. This technique has recently been improved and used to measure the surface displacement field of an object at high temperature. The development of a PC based Sub-Pixel Digital Image Correlation system has yielded an accurate and easy to use system for measuring surface displacements and gradients. Experiments have been performed to show the system is viable for measuring thermal strain.

Mcneill, Stephen R.↗

DOE OSTI2018

Microstructural strain mapping during in-situ cyclic testing of ductile iron

Highlights: • A method for quantitative study of crack formation and propagation during cyclic loading was developed. • Focused Ion Beam Milling was shown to be an effective method to generate a high quality speckle pattern for Digital Image Correlation measurements • The method enabled a high-resolution measurement of localized strain in the microstructure of ductile iron • The peak strain and the strain distribution ahead of the growing crack under load were quantified - Abstract: This paper focuses on local strain distribution in the microstructure of high silicon ductile iron during cyclic loading. In-situ cyclic test was performed on compact-tension (CT) samples inside the scanning electron microscope (SEM) to record the whole deformation and obtain micrographs for microstructural strain measurement by means of digital image correlation (DIC) technique. Focused ion beam (FIB) milling was used to generate speckle patterns necessary for DIC measurement. The equivalent Von Mises strain distribution was measured in the microstructure at the maximum applied load. The results revealed a heterogeneous strain distribution at the microstructural level with higher strain gradients close to the notch of the CT sample and accumulated strain bands between graphite particles. Local strain ahead of the early initiated micro-cracks was quantitatively measured, showing high strain localization, which decreased by moving away from the micro-crack tip. It could be observed that the peak of strain in the field of view was not necessarily located ahead of the micro-cracks tip which could be because of the (i) strain relaxation due to the presence of other micro-cracks and/or (ii) presence of subsurface microstructural features such as graphite particles that influenced the strain concentration on the surface.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Theoretical analysis on the measurement errors of local 2D DIC: Part I temporal and spatial uncertainty quantification of displacement measurements

This study presents a theoretical uncertainty quantification of displacement measurements by subset-based 2D-digital image correlation. A generalized solution to estimate the random error of displacement measurement is presented. The obtained solution suggests that the random error of displacement measurements is determined by the image noise, the summation of the intensity gradient in a subset, the subpixel part of displacement, and the interpolation scheme. The proposed method is validated with virtual digital image correlation tests.

2D-DIC↗

DOE OSTI2024

Chemo-Mechanical Instabilities in Lithium Cobalt Oxide at Higher State-Of-Charge in Li-Ion Batteries

Transition metal oxide cathodes are widely used in commercial Li-ion batteries. However, their practical charge capacity is limited due to severe chemo-mechanical instabilities at higher charge voltage, and state-of-charge condition. Here, in situ stress and strain measurements were synchronized to probe mechanical deformations in the lithium cobalt oxide (LCO) cathode via a multi-beam stress sensor and digital image correlation, respectively. In situ mechanical measurements revealed how Li removal from the electrode structure induces deformations on the LCO composite cathodes during cycling. The structure and morphology of the LCO cathodes were further investigated by X-ray diffraction (XRD) and scanning electron microscopy (SEM) studies. Two distinct electrochemical and mechanical behaviors were identified when the LCO was charged up to 4.65 V. The LCO undergoes a compressive stress generation when charged up to 4.2 V and surface fractures on the LCO particles were detected by SEM. LCO cathode experienced significantly large contractions (negative strains) when charged up to 4.65 V, where intergranular crack formation and phase transformation were detected on the LCO particles via SEM and XRD, respectively. Overall, the study bridges complicated structural deformations with in situ analysis of mechanical degradations in LCO cathodes charged at higher voltages. The correlation is vital to understanding instability mechanisms in transition metal oxides at high voltages for alkali metal ion batteries.

higher state-of-charge↗

DOE OSTI2013

A feasibility study for experimentally determining dynamic force distribution in a lap joint

Developing constitutive models of the physics in mechanical joints is currently stymied by inability to measure forces and displacements within the joint. The current state of the art estimates whole joint stiffness and energy loss per cycle from external measured force input and one or two acceleration responses. To validate constitutive models beyond this state requires a measurement of the distributed forces and displacements at the joint interface. Unfortunately, introducing measurement devices at the interface completely disrupts the desired physics. A feasibility study is presented for a non-intrusive method of solving for the interface dynamic forces from an inverse problem using full field measured responses. The responses come from the viewable surface of a beam. The noise levels associated with digital image correlation and continuous scanning laser Doppler velocimetry are evaluated from typical beam experiments. Two inverse problems are simulated. One utilizes the extended Sum of Weighted Accelerations Technique (SWAT). The second is a new approach dubbed the method of truncated orthogonal forces. These methods are much more robust if the contact patch geometry is well identified. Various approaches to identifying the contact patch are investigated, including ion marker tracking, Prussian blue and ultrasonic measurements. A typical experiment is conceived for a beam which has a lap joint at one end with a single bolt connecting it to another identical beam. In a virtual test using the beam finite element analysis, it appears that the SWAT inverse method requires evaluation of too many coefficients to adequately identify the force distribution to be viable. However, the method of truncated orthogonal forces appears viable with current digital image correlation (and probably other) imaging techniques.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

In Situ Probing Potassium-ion Intercalation-induced Amorphization in Crystalline Iron Phosphate Cathode Materials

Na-ion and K-ion batteries are promising alternatives for large-scale energy storage applications due to their abundance and low cost. Intercalation of these large ions could cause irreversible structural deformation and partial to complete amorphization in the crystalline electrodes. The designing of new amorphous electrodes is another route to develop electrodes to store these ions reversibly. Lack of understanding of dynamic changes in the amorphous nanostructures during battery operation is the bottleneck for further developments. Here, we report the utilization of in situ digital image correlation and in-operando X-ray diffraction (XRD) techniques to probe dynamic changes in the amorphous phase of iron phosphate during potassium intercalation. In-operando XRD demonstrates amorphization in the electrode’s nanostructure during the first charge/discharge cycle. Additionally, the ex-situ high-resolution transmission electron microscopy further confirms the amorphization after potassium insertion. In situ strain analysis detects the reversible deformation associated with redox reactions in the amorphous phases. Our approach offers new insights on the mechanisms of ion intercalation in the amorphous nanostructures which are highly potent for development of next-generation batteries.

Ozdogru, Bertan↗

DOE OSTI2016

Complete Status Report Documenting Weld Development for Thin Wall Tubing of ODS Ferritic Alloys

Beginning in 2015, research in the FCRD program began the development of FSW for joining thin sections of 14YWT in the form of thin (0.5 mm) plate and ultimately thin wall tubing. In the previous fiscal year, a ~1 mm thick plate, or sheet, of 14YWT was produced by hot rolling with no edge cracking. The initial FSW experiment was performed on the 1 mm thick plate and involved a bead-on-plate weld in which the spinning pin tool is plunged into the plate surface, but does not penetrate the thickness of the plate, and then travels the length of the plate. The FSW run successfully produced a bead-on-plate stir zone on the 1 mm thick plate of 14YWT, but no characterization studies of the stir zone were performed by the end of FY15. Therefore, the results presented in this report cover the microstructural analysis of the bead-on-plate stir zone and the initial research task on obtaining tensile properties of the stir zone using the digital image correlation (DIC) approach during testing of miniature tensile specimens to assess the quality of the FSW parameters used in the initial experiment. The results of the microstructural characterization study using optical, scanning electron and scanning transmission electron microscopies showed the grain structure in the SZ to have isotropic and irregular shape but very similar size compared to the highly elongated grains oriented horizontally with the plane of the plate that were observed in the unaffected zone of 14YWT. Several cracks oriented horizontally were observed mostly on the retreating side of the SZ in both the SZ and TMAZ. These cracks may have formed due to insufficient pressure being exerted on the top surface of the plate by the shoulder and pin tool during the FSW run. High resolution STEM-EDS analysis showed the presence of the Y-Ti-O particles in the SZ, but that some particles exhibited coarsening. Overall, the FSW parameters used to produce the bead-on-plate SZ in the 0.1 cm thick plate of 14YWT were nearly optimized. The results of the digital image correlation (DIC) analysis of the two SS-Mini-2 tensile specimens fabricated from the 0.1 cm thick plate of 14YWT showed that the specimens exhibited high strength and good ductility. However, strain localization occurred in one of the specimens during the tensile test that was too close to the grips, which invalidated the data from the DIC analysis. This was surprising since the abrupt crack pop-in that occurred in the 0.1 cm thick plate of 14YWT during fabrication by wire EDM suggested that residual stresses were high. Residual stress measurements and the effects of post weld heat treatment on the FSW quality of joined 14YWT plates will be investigated in the next FW work package.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Tuscaloosa Marine Shale Laboratory

The Tuscaloosa Marine Shale (TMS) in Louisiana and Mississippi is an Upper Cretaceous source rock formation sandwiched between the sands of the upper and lower Tuscaloosa sections. The TMS is believed to be the source rock for underlying prolific Tuscaloosa sand formation. The TMS has an unproven estimate of 7,000,000,000 bbls of recoverable oil while its current total average production is about 3,000 bbls of oil per day in 2017. In 2013 and 2014, more than 80 wells were drilled horizontally into the TMS that were fractured using multi-stage fracturing technology. The results from this have been mixed, but recent production for several wells show an appealing initial oil production rate of more than 1000 bbl/day. The preliminary core analysis by industry partners and a few literature studies shows that the TMS is one of the most clay-rich and sensitive shales to water. Due to these and other technical problems, there is high risk for the economic development of TMS compared to other shale plays. The experiences of major industrial players in the TMS show the necessity of open and collaborative efforts to better understand the critical gaps in the development of this challenging and potentially highly economic shale play to enable more cost-efficient and environmentally-sound recovery from this unconventional liquid-rich shale play. The overall objective of this project is to form a consortium of science and industry partners to address the following six major objectives using scientific and technical approaches: 1. To improve wellbore integrity by better understanding the sources of the wellbore instability issues, proposing innovative mud and cement design for the TMS. 2. To improve formation evaluation using laboratory techniques for the evaluation of mineralogical composition, organic content, and produced-water chemistry as well as well log and geophysical analysis. 3. To determine the role of geologic discontinuities on fracture growth and shale creep behavior using digital image correlation technique. 4. To investigate the application of stable CO 2 foam and super-hydrophobic proppants for improved reservoir stimulation. 5. To better understand the nature of water/hydrocarbon/CO 2 flow in clay and organic-rich formation and the role of water/fluid interaction on recovery. 6. To prepare better socio-economic environment for TMS development by community engagement. Subsequently, the TMS virtual laboratory conducted testing and analysis of various properties of rock and formation fluids from the TMS, including but not limited to the following: Analyzing reports and logs to better understand the source of wellbore instability in TMS wells; Experiments to design a customized cement based on TMS requirements; Experiments to obtain the mineralogical and geochemical composition of TMS samples; Seismic analysis of TMS geophysical data to better predict total organic carbon (TOC) content and brittleness in TMS; Well log analysis to better estimate the TOC and geo-mechanical properties of TMS; Experiments on formation water to understand the chemistry of produced water; Experiments to determine the role of lamination and natural fractures on fracture propagation or rock deformation using digital image correlation technique in in-direct tensile tests, semi-circular bend test and creep tests Experiments to determine the stability and rheological properties of nanoparticle-stabilized CO 2 foam in TMS rock samples; Experiments to determine fluid dynamics in un-propped TMS fractures and the role of nano-coating of proppants on fluid dynamics in fractures with proppants; Micro-fluidics experiments to enhance the understanding of fluid dynamics in tight liquidrich pores with high clay content; Socio-economic studies to better engage communities in TMS development.

58 GEOSCIENCES↗

DOE OSTI2014

Transient x-ray diffraction with simultaneous imaging under high strain-rate loading

Real time, in situ, multiframe, diffraction, and imaging measurements on bulk samples under high and ultrahigh strain-rate loading are highly desirable for micro- and mesoscale sciences. We present an experimental demonstration of multiframe transient x-ray diffraction (TXD) along with simultaneous imaging under high strain-rate loading at the Advanced Photon Source beamline 32ID. The feasibility study utilizes high strain-rate Hopkinson bar loading on a Mg alloy. The exposure time in TXD is 2–3 μs, and the frame interval is 26.7–62.5 μs. Various dynamic deformation mechanisms are revealed by TXD, including lattice expansion or compression, crystal plasticity, grain or lattice rotation, and likely grain refinement, as well as considerable anisotropy in deformation. Dynamic strain fields are mapped via x-ray digital image correlation, and are consistent with the diffraction measurements and loading histories.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRSDate not supplied

Utilizing 3D-DIC on Mars 2020 Rover Wheel Assembly: Test-Analysis Correlation

Following the successful implementation of full-field photogrammetry, more specifically three-dimensional Digital Image Correlation (3D-DIC), on the Mars 2020 Heat Shield Structural Failure Review assessment, 3D-DIC was selected as one of the primary measurement techniques for the Mars 2020 Rover wheel assembly qualification test at the NASA Jet Propulsion Laboratory (JPL). To validate the Rover wheel landing loads simulations, it was extremely important to have high confidence in the wheel models. Due to the large deformations and strains that the wheel would be subject to during landing, traditional instrumentation such as linear variable displacement transducers (LVDTs), electrical-resistance strain gages and string potentiometers, would not be sufficient on their own to provide all the necessary validation data. Therefore, the NASA Engineering and Safety Center (NESC) provided the 3D-DIC expertise and support to measure the high deformation and strain in the wheel flexures and qualify the overall structural response of the Mars 2020 rover wheel assembly. There were two key objectives for the photogrammetry technique: (1) monitor the wheel response in real-time, guarding against anomalous behavior and failure, and (2) provide test data for test-analysis correlation to validate and/or improve the high-fidelity computational model. The contents of this paper will focus on the challenges of applying 3D-DIC to the Mars 2020 Rover wheel assembly and how these challenges were overcome. Examples of test-analysis correlation during the stiffness characterization and structural qualification will be presented and discussed in detail. Experimental results were compared with the analysis and showed excellent agreement between the predicted behavior and helped validate the high-fidelity models.

Mars 2020 Rover Wheel↗

NASA NTRS1990

Image correlation nondestructive evaluation of impact damage in a glass fiber composite

Presented in viewgraph format, digital image correlation, damage in fibrous composites, and damaged coupons (cross-ply scotchply GI-Ep laminate) are outlined. It was concluded that the image correlation accuracy was 0.03 percent; strains can be processed through Tsai-Hill failure criteria to qualify the damage; the statistical data base must be generated to evaluate certainty of the damage estimate; size effects need consideration; and better numerical techniques are needed.

Russell, Samuel S.↗