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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

A study of the deformation and failure mechanisms of protective intermetallic coatings on AZ91 Mg alloys using microcantilever bending

In this study, a nanoindentation-based microcantilever bending technique was utilized to investigate the interfacial properties of a β-Mg{sub 17}Al{sub 12}/AZ91 Mg alloy film/substrate system under tensile loading conditions. Finite element analysis (FEA) was first undertaken to optimise the design of cantilever structures for inducing high tensile stresses at the interface. Cantilevers consisting of a necked region or notch at the interface were determined to be the most successful designs. Microcantilevers containing the β-Mg{sub 17}Al{sub 12}/AZ91 interface were then made using focused ion beam (FIB) milling technique. Necks were made in the cantilevers to intensify the tension at the interface and notches were used to introduce a stress concentration to the interface. During bending, the cantilevers were deflected to failure. Subsequent analysis of the deformed cantilevers using electron microscopies revealed that plastic deformation, and subsequent ductile rupture, of the AZ91 phase was the dominant failure mechanism. When the β-Mg{sub 17}Al{sub 12}/AZ91 film/substrate system was subjected to tension, the softer AZ91 phase failed prior to interfacial delamination, demonstrating that the strength of the interface exceeded the stresses that caused ductile failure in the substrate material. - Highlights: •Microcantilever bending was used to study the property of film/substrate interface. •FEA was used to optimise cantilever design for achieving high interfacial tension. •The intermetallic coatings on AZ91 substrate have strong interfacial adhesion.

36 MATERIALS SCIENCE↗
NASA NTRS2017

Material Characterization for the Analysis of Skin/Stiffener Separation

Test results show that separation failure in co-cured skin/stiffener interfaces is characterized by dense networks of interacting cracks and crack path migrations that are not present in standard characterization tests for delamination. These crack networks result in measurable large-scale and sub-ply-scale R curve toughening mechanisms, such as fiber bridging, crack migration, and crack delving. Consequently, a number of unknown issues exist regarding the level of analysis detail that is required for sufficient predictive fidelity. The objective of the present paper is to examine some of the difficulties associated with modeling separation failure in stiffened composite structures. A procedure to characterize the interfacial material properties is proposed and the use of simplified models based on empirical interface properties is evaluated.

Davila, Carlos G.↗
NASA NTRS2011

Power Distribution for Cryogenic Instruments at 6-40K The James Webb Space Telescope Case

The Integrated Science Instrument Module (ISIM) of the James Webb Space Telescope (JWST) operates its instruments passively cooled at around 40 Kelvin (K), with a warm Instrument Electronic Compartment (IEC) at 300K attached to it. From the warm electronics all secondary signal and power harnesses have to bridge this 300-40K temperature difference and minimize the power dissipation and parasitic heat leak into the cold region. After an introduction of the ISIM with its instruments, the IEC with the electronics, and the harness architecture with a special radiator, this paper elaborates on the cryogenic wire selection and tests performed to establish current de-rating rules for different wire types. Finally failure modes are analyzed for critical instrument interfaces that could inject excessive currents and heat into the harness and cold side, and several solutions for the removal of such failures are presented.

Rumler, Peter↗
NASA NTRS1994

Thermal Testing of High Performance: Thermal Barrier Coatings for Turbine Blades

A 350 micron thick 7 wt.% Y 2 O 3 -ZrO 2 (7YSZ) ceramic Thermal Barrier Coating (TBC) was manufactured in an argon atmosphere and with a strictly controlled substrate temperature on flat IN 600 samples and on IN 100 aircraft turbine blades. This new atmosphere and temperature controlled spraying (ATCS) allows the reduction of the residual stresses and an improvement in the microstructure and in the mechanical properties of the coating. The good performance of these new TBC's was assessed in thermal fatigue and in thermal shock tests carried out in air at 1100°C and at 1280°C respectively. The oxidation rate of the metal-ceramic interface was measured at 1100°C. Failure of the TBC's was induced only by the deterioration (like oxidation, cracking, ...) of the uncoated parts of the samples, as testing temperature was too severe for the base metals. Spalling was thereafter driven by compressive stresses near the aluminum oxide layer at the metal-ceramic interface. The results of these tests underline the good quality of the ceramic coating manufactured by the new ATCS technology.

L Bertamini↗
NASA NTRS1991

Mechanical behavior of fiber reinforced SiC/RBSN ceramic matrix composites: Theory and experiment

The mechanical behavior of continuous fiber reinforced SiC/RBSN (Reaction Bonded Silicon Nitride) composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE (nondestructive evaluation) techniques through the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorporating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytical predictions.

Chulya, Abhisak↗
NASA NTRS1991

Mechanical behavior of fiber reinforced SiC/RBSN ceramic matrix composites - Theory and experiment

The mechanical behavior of continuous fiber reinforced SiC/RBSN (Reaction Bonded Silicon Nitride) composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE (nondestructive evaluation) techniques throughout the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorproating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytical predictions.

Chulya, Abhisak↗
DOE OSTI2019

Axial Tensile Failure Analysis of SiC{sub f}/Ti Composite Based on Continuum Cohesive Zone Model

In this paper, the failure behavior of SiC fiber-reinforced Ti-6Al-4V matrix composite (SiC{sub f}/Ti) under longitudinal loads was studied experimentally and theoretically. Experimental results show that the interface of SiC{sub f}/Ti composite is continuous and integral. Through SEM observations, it was found that transverse matrix cracks initiated from the debonding region of the interface. A three-dimensional representative volume element was developed to simulate the failure process of SiC{sub f}/Ti-6Al-4V composite. A continuum cohesive zone model is employed to describe the debonding behavior at the interface, compared with a discrete one. More accurate simulated results were obtained by a continuum cohesive zone model, corresponding to experimental results. The transverse cracking behavior of the matrix was simulated. The stress–strain curves predicted by the continuum cohesive zone model show a good agreement with the experimental results. The fiber volume fraction, interface strength and interface toughness are investigated to exhibit their influences upon the longitudinal mechanical characteristics of SiC{sub f}/Ti-6Al-4V composite.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Rapid interface flaw extension with friction

An idealized two-dimensional example of rapid interface flow extension is described. Initially undisturbed dissimilar isotropic, homogeneous, linearly elastic half-spaces are perfectly bonded along the interface y=0. Quantities associated with the half-space or = to 0 are denoted by the prime superscript or the subscripts 3 or 4 while those in y or = to 0 carry the subscripts 1 or 2. At time t=0 adjacent material points at x=0, y= + or - 0 are forced apart horizontally with a constant relative velocity delta v. This results in a zone of bond failure which extends symmetrically along the interface at a constant rate c. The newly created flaw surfaces are in sliding contact resisted by Coulomb friction. The friction coefficient is gamma.

Brock, L. M.↗
NASA NTRS2020

Application of Fault Containment Principles to EMC

A hardware fault in aerospace is an undesired response to a designed engineering function in hardware. Therefore, in aerospace systems fault management is of prime importance. An important aspect of hardware faults is fault propagation. Fault propagation (also known as failure propagation) is a condition where a fault will not only produce an undesired hardware response, at its location of origin, but the fault will also propagate to other interfaced hardware and cause additional faults, or failures. Fault containment is necessary to avoid fault propagation. A fault containment region is an electronic or electromechanical region within a given hardware assembly where a fault in that region will not physically propagate to other regions of the assembly, and beyond. Rather, the fault will cause a functional failure of the hardware, where the fault occurred, without causing any additional propagated failures. Electromagnetic Compatibility (EMC) is a desired state in aerospace hardware. Electromagnetic Interference (EMI) in aerospace hardware is a fault condition of EMC. Like other faults EMI can also propagate to other aerospace hardware unless it occurs inside an EMI containment region. The paper addresses the concepts of fault containment region and introduces the concept of EMI containment region with examples of both.

Perez, Reinaldo↗
DOE OSTI2019

Mesoscale modeling of hypervelocity impacts using the CTH shock physics code

Material fragmentation after a hypervelocity impact is vital to predictive electro-optical and infrared (EO/IR) modeling. Successful comparisons with data require that hot, submicron fragments are generated in such impacts; yet, experimental data has so far been unable to produce fragments of this scale. The purpose of this work was to investigate how modeling assumptions of macro-scale, bulk materials might influence the generation of debris in hypervelocity impacts and ultimately the predicted EO/IR signatures of these debris clouds. Sphere-on-plate impact simulations simplified the comparison of different modeling approaches. In one set of simulations, materials were modeled with the traditional, bulk approach. Those findings were compared to simulations run with the mesoscale material grain structure explicitly modeled. This study focused on the comparison of two parameters that are tied directly to the EO/IR signature: strain rate at failure (a proxy for debris fragment size) and material temperature. Interfaces between grains, here due to void insertion, resulted in the most notable change in both the strain rate at failure and material temperature. Shock reflections from grain-void interfaces induced higher strain rates and material temperatures, and it is expected that similar effects may be produced from inclusions or dislocations in real materials. Thus, interfaces within a material may play an important role in producing smaller hot debris frag

42 ENGINEERING↗
DOE OSTI2023

Crack Growth Rate at Oxygen Electrode/Electrolyte Interface in Solid Oxide Electrolysis Cells Predicted by Experiment Coupled Multiphysics Modeling

Solid oxide electrolysis cell (SOEC) is a very efficient hydrogen production technology, but the cell degradation is a serious limiting factor for its long-term implementation. Oxygen electrode (OE) delamination is reported to be the critical degradation mechanism. In this study, we present a methodology to understand the delamination failure of the OE due to chemical stress in a better perspective. Several OE configurations were tested: baseline strontium-doped lanthanum cobalt iron oxide (LSCF) single layer design and tantalum-doped strontium cobalt oxide (SCT) - LSCF bilayer designs with different SCT loadings. An electro-chemo-mechanical model is developed to associate the electrochemical behavior of the cell with solid mechanics for calculating crack growth of the cell during long term test. The bilayer configuration with SCT 20 wt% has better performance as it survived in the long-term life test with the least crack length. This study implies that an additional nano-coating of SCT over the OE have improved the species transport and oxygen evolution with reduced chemical stress. As the operating current density decreases, it takes longer time for the cell to reach the delamination with the same critical crack length of 6.5 μ m (∼93% of the electrode/electrolyte interface length). Finally, it was concluded that chemical stress plays a significant role in interface delamination failure, however it may not be the only source of stresses at the interface.

08 HYDROGEN↗
DOE OSTI2022

Multiphysics modeling of SOFC performance degradation caused by interface delamination and active layer cracking

In solid oxide device operation, delamination and cracking cause more catastrophic damage to cell life than other degradation mechanisms, leading to more rapid cell failure. The electrochemical performance degradation caused by electrode/electrolyte interface delamination and active layer cracking were investigated through in-house developed three-dimensional multiphysics simulations. Here the multiphysics simulations, fully calibrated against experimental datasets for button cells in a previous study, were extended to quantitatively investigate the effects of electrode/electrolyte interface delamination and active layer cracking. The simulated polarization curves and impedance behavior with various levels of delamination and cracking provided insights of the performance degradation. Furthermore, the local current distributions within the cell were analyzed for three different operating modes: constant voltage, constant current, and constant power. Finally, a practical strategy was proposed to mitigate the performance degradation in the realistic cell operations, extending overall cell lifetime.

08 HYDROGEN↗
DOE OSTI2020

Improved Stability and Cyclability of Ceramic Solid Electrolyte by Coating Polymer

Rechargeable all-solid-state lithium (Li) metal batteries show better safety and energy density compared to commercial Li-ion batteries using liquid electrolyte. As the key component of Li metal batteries, ceramic solid-state electrolyte has attracted great interest because of its high ion conductivity and great potential in interfacing with Li metal. Ceramic electrolyte has a more stable interface with Li metal than liquid electrolyte, but chemical reaction and Li dendrite growth at the electrolyte/Li interface are still significant, which causes device degradation and failure by cycling of Li plating and stripping. Unlike ceramic electrolyte, polymer electrolyte has a relatively stable interface with Li metal and better mechanical flexibility. Therefore, we introduced a polymer electrolyte coating to protect the ceramic electrolyte from direct contact with Li metal. The galvanotactic cycling Li plating/striping data on the devices with (without) the coating illustrates increased (decreased) overall conductivity and cyclability of the test cell by the cycling. Nanometer-scale ionic-transport imaging, based on atomic force microscopy, shows that cycling degrades the ceramic-only electrolyte by partially blocking ionic transport in areas; in contrast, cycling on the polymer-coated electrolyte improves ionic conductivity. Compared with the ceramic-only electrolyte, this novel polymer electrolyte coating on ceramic electrolyte shows less degradation when in contact with Li metal.

25 ENERGY STORAGE↗
DOE OSTI2017

Microstructure Evolution and Failure Analysis of an Aluminum–Copper Cathode Conductive Head Produced by Explosive Welding

In this paper, microstructure evolution and failure analysis of the aluminum-copper interface of cathode conductive heads during their use were studied. The interface morphologies, compositions, conductivity and mechanical properties were investigated and analyzed. Obvious corrosion was found on the surface of the contact interface, which was more prevalent on an Al matrix. The crack increased sharply in the local metallurgical bonding areas on the interface, with the compound volume having no significant change. The phase transformation occurred on the interface during use, which was investigated using the elemental composition and x-ray diffraction pattern. The microhardness near the interface increased accordingly. An obvious electrical conductivity decrease appeared on the Al/Cu interface of the cathode conductive head after use over a specific time interval. Therefore, the deterioration of the microstructures and corrosion are the primary factors that affect the electrical conductivity and effective bonding, which will lead to eventual failure.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Multiscale Modeling of Intergranular Fracture in Aluminum: Constitutive Relation For Interface Debonding

Intergranular fracture is a dominant mode of failure in ultrafine grained materials. In the present study, the atomistic mechanisms of grain-boundary debonding during intergranular fracture in aluminum are modeled using a coupled molecular dynamics finite element simulation. Using a statistical mechanics approach, a cohesive-zone law in the form of a traction-displacement constitutive relationship, characterizing the load transfer across the plane of a growing edge crack, is extracted from atomistic simulations and then recast in a form suitable for inclusion within a continuum finite element model. The cohesive-zone law derived by the presented technique is free of finite size effects and is statistically representative for describing the interfacial debonding of a grain boundary (GB) interface examined at atomic length scales. By incorporating the cohesive-zone law in cohesive-zone finite elements, the debonding of a GB interface can be simulated in a coupled continuum-atomistic model, in which a crack starts in the continuum environment, smoothly penetrates the continuum-atomistic interface, and continues its propagation in the atomistic environment. This study is a step towards relating atomistically derived decohesion laws to macroscopic predictions of fracture and constructing multiscale models for nanocrystalline and ultrafine grained materials.

Yamakov, V.↗
DOE OSTI2016

Spent Nuclear Fuel Vibration Integrity Study

The objective of this research is to collect dynamic experimental data on spent nuclear fuel (SNF) under simulated transportation environments using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT), the hot-cell testing technology developed at Oak Ridge National Laboratory (ORNL). The collected CIRFT data will be utilized to support ongoing spent fuel modeling activities, and support SNF transportation related licensing issues. Recent testing to understand the effects of hydride reorientation on SNF vibration integrity is also being evaluated. CIRFT results have provided insight into the fuel/clad system response to transportation related loads. The major findings of CIRFT on the HBU SNF are as follows: SNF system interface bonding plays an important role in SNF vibration performance, Fuel structure contributes to the SNF system stiffness, There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interaction, and SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. Because of the non-homogeneous composite structure of the SNF system, finite element analyses (FEA) are needed to translate the global moment-curvature measurement into local stress-strain profiles. The detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained directly from a CIRFT system measurement. Therefore, detailed FEA is used to understand the global test response, and that data will also be presented.

bending fatigue↗
DOE OSTI2016

Spent nuclear fuel dynamic performance under normal conditions of transport

The objective of this project is to evaluate the spent nuclear fuel (SNF) vibration integrity under normal condition of transport. The SNF fatigue strength data has been collected from various pressurized water reactors. The CIRFT (Cyclic Integrated Reversible-Bending Fatigue Tester) has been used to simulate transportation environments. CIRFT is an enabling hot-cell testing technology developed at Oak Ridge National Laboratory (ORNL). The CIRFT consists mainly of a U-frame testing setup and a real-time curvature measurement method. The three-component U-frame setup of the CIRFT has two rigid arms and linkages to a universal testing machine. The curvature of rod bending is obtained through a three-point deflection measurement method. Three linear variable differential transformers (LVDTs) are used and clamped to the side connecting plates of the U-frame to capture the deformation of the rod. CIRFT results have provided insight into the fuel/clad system response to transportation related loads. Because of the non-homogeneous composite structure of the SNF system, finite element analyses (FEA) are needed to translate the global moment-curvature measurement into local stress-strain profiles. The detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained directly from a CIRFT system measurement. Therefore, detailed FEA is used to understand the global test response. The major findings of CIRFT test on the high burn-up SNF are as follows: -) SNF system interface bonding plays an important role in SNF vibration performance; -) Fuel structure contributes to the SNF system stiffness; -) There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interaction, and -) SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous.

42 ENGINEERING↗
DOE OSTI2016

Spent Nuclear Fuel Vibration Integrity Study - 16332

The objective of this research is to collect dynamic experimental data on spent nuclear fuel (SNF) under simulated transportation environments using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT), the hot-cell testing technology developed at Oak Ridge National Laboratory (ORNL). The collected CIRFT data will be utilized to support ongoing spent fuel modeling activities, and support SNF transportation related licensing issues. Recent testing to understand the effects of hydride reorientation on SNF vibration integrity is also being evaluated. CIRFT results have provided insight into the fuel/clad system response to transportation related loads. The major findings of CIRFT on the HBU SNF are as follows: - SNF system interface bonding plays an important role in SNF vibration performance, - Fuel structure contributes to the SNF system stiffness, - There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interaction, and - SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. Because of the non-homogeneous composite structure of the SNF system, finite element analyses (FEA) are needed to translate the global moment-curvature measurement into local stress-strain profiles. The detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained directly from a CIRFT system measurement. Therefore, detailed FEA is used to understand the global test response, and that data will also be presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗