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DOE OSTI2016

Experimentally Determined Anisotropic Yield Surfaces for Al 7079

Isotropic von Mises and anisotropic Hill yield surfaces for Al 7079 were fit using experimental data gathered from 12 dog-bone specimens that captured the highly variable microstructural texture of the aluminum alloy. Strain gauges or the digital image correlation technique were utilized to determine the strain histories in the specimen as they were subjected to uniaxial tension. The final yield surface fits displayed a high degree of variability that was dependent upon how the yield functions were calculated, i.e. which size and shape information was used. The findings display that a model with a higher number of anisotropic parameters is needed to better and more consistently capture the anisotropic properties of Al 7079, such as the Barlat, Yld2004-18, model that has 20 parameters.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Biaxial deformation in high purity aluminum

The convergence of multiple characterization tools has been applied to investigate the relationship of microstructure on damage evolution in high purity aluminum. The extremely coarse grain size of the disc-shaped sample provided a quasi-two dimensional structure from which the location of surface-measured features could be inferred. In particular, the role of pre-existing defects on damage growth was accessible due to the presence of casting porosity in the aluminum. Micro tomography, electron backscatter diffraction, and digital image correlation were applied to interrogate the sample in three dimensions. Recently micro-bulge testing apparatus was used to deform the pre-characterized disc of aluminum in biaxial tension, and related analysis techniques were applied to map local strain fields. Subsequent post-mortem characterization of the failed sample was performed to correlate structure to damaged regions. We determined that strain localization and associated damage was most strongly correlated with grain boundary intersections and plastic anisotropy gradients between grains. Pre-existing voids played less of an apparent role than was perhaps initially expected. Finally, these combined techniques provide insight to the mechanism of damage initiation, propagation, and failure, along with a test bed for predictive damage models incorporating anisotropic microstructural effects.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Rate-dependent strength and deformation heterogeneity of B4C-reinforced Al composite: Time-resolved imaging with synchrotron X-rays

Dynamic (up to 5500 s -1 ) and quasi-static compression tests are conducted on a 15 wt% B4C particle-reinforced Al (B 4 C/Al) composite. In situ, high-speed synchrotron X-ray phase contrast imaging and digital image correlation are employed to map mesoscale deformation fields at μm and μs scales. The bulk stress–strain curves show significant strain and strain-rate hardening under dynamic compression. The strain-rate sensitivity exponent is an order of magnitude higher at high strain rates (> 10 3 s -1 ) than that at low strain rates (< 10 -2 s -1 ). Strain field mapping demonstrates distinct compressive strain localizations for both quasi-static and dynamic loading. Nevertheless, compressive strain localizations appear denser in spacing under dynamic loading, owing to spontaneous dislocation nucleation in both weak and strong zones. This results in a higher density of geometrically necessary dislocations, which contributes to the higher strain and strain-rate hardening of B 4 C/Al under dynamic loading. Additionally, the ratio of the maximum local strain to the bulk average is 1.5, and the local strain-rate enhancement cannot explain the increased rate sensitivity of B 4 C/Al under dynamic loading. Therefore, the rate-dependent deformation heterogeneity dominates the strain-rate hardening of B 4 C/Al. Postmortem analyses help correlate deformation features to particle- and grain-scale microstructures, yielding consistent results with mesoscale strain fields.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Effect of Topology on Transient Dynamic and Shock Response of Polymeric Lattice Structures

Architected cellular materials, such as lattice structures, offer potential for tunable mechanical properties for dynamic applications of energy absorption and impact mitigation. In this work, the static and dynamic behavior of polymeric lattice structures was investigated through experiments on octet-truss, Kelvin, and cubic topologies with relative densities around 8%. Here, dynamic testing was conducted via direct impact experiments (25–70 m/s) with high-speed imaging coupled with digital image correlation and a polycarbonate Hopkinson pressure bar. Mechanical properties such as elastic wave speed, deformation modes, failure properties, particle velocities, and stress histories were extracted from experimental results. At low impact velocities, a transient dynamic response was observed which was composed of a compaction front initiating at the impact surface and additional deformation bands whose characteristics matched low strain-rate behavior. For higher impact velocities, shock analysis was carried out using compaction wave velocity and Eulerian Rankine–Hugoniot jump conditions with parameters determined from full-field measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Non-invasive measurement of proppant pack deformation

In this study, we describe a method to non-invasively study the movement of proppant packs at the sub-fracture scale by applying three-dimensional digital image correlation techniques to X-ray tomography data. Proppant movement is tracked in a fractured core of Marcellus shale placed under a series of increasing confining pressures up to 10,000 psi. The analysis reveals the sudden failure of a region of the proppant pack, accompanied by the large-scale rearrangement of grains across the entire fracture surface. The failure of the pack coincides with the appearance of vortex-like grain motions similar to features observed in biaxial compression of two dimensional granular assemblies.

02 PETROLEUM↗

NASA NTRS2022

Detecting Flow-Induced Vibration in Bellows

The NESC performed testing to determine if high-speed video techniques can be used to predict the onset of flow-induced vibrations (FIV) in bellows. A comprehensive test matrix was established to determine if Motion Magnification (MM) and Digital Image Correlation (DIC) can be used to determine the onset of FIV in straight and gimbaled bellows. Several of the tests were intended to determine if MM and DIC can establish the resonant frequencies of the bellows with no a priori knowledge. The results of the MM and DIC were compared with data from strain gages and microphones. Although the testing was limited to one single-ply unshielded bellows, this effort provided the proof-of-concept that MM and DIC are feasible methods for determining the onset of FIV in bellows.

Flow-induced vibration↗

DOE OSTI2020

The effect of microstructure on the relationship between grain boundary sliding and slip transmission in high purity aluminum

The relationship between grain boundary sliding (GBS) and slip transmission is investigated experimentally at grain boundaries in 99.99% aluminum with a through-thickness, coarse grained microstructure deformed in tension at 190 °C. Using scanning electron microscope enabled digital image correlation (SEM-DIC) and electron backscatter diffraction (EBSD), high resolution strain fields and microstructural information were measured to examine the influence of microstructural neighborhoods on interactions between GBS and slip transmission and strain localization. Several distinct cases are presented that highlight important microstructural factors that govern deformation near grain boundaries. The findings include (1) direct transmission and GBS were anti-compatible and facilitated by opposing boundary types (low misorientation and high energy grain boundaries respectively); (2) increased GBS activity was correlated with decreased indirect transmission behavior; (3) GBS accommodation at triple junctions was enabled by intragranular plasticity; and (4) the local intragranular plastic strain discontinuity between grains determined the magnitude of GBS gradients. Finally, this work provides insight into the nature of these mechanisms and can be used to identify strain transfer criteria that can lead to improved GBS-sensitive crystal plasticity models.

36 MATERIALS SCIENCE↗

NASA NTRS2014

Mechanical Behavior of Microelectromechanical Microshutters

A custom micro-mechanical test system was constructed using off-the-shelf components to characterize the mechanical properties of microshutters. Microshutters are rectangular microelectromechanical apertures which open and close about a narrow torsion bar hinge. Displacement measurements were verified using both capacitive and digital image correlation techniques. Repeatable experiments on Si3N4 cantilever beams verified that the test system operates consistently. Using beam theory, the modulus of elasticity of the low stress Si3N4 was approximately 150 GPa, though significant uncertainty exists for this measurement due primarily to imprecise knowledge of the cantilever thickness. Tests conducted on microshutter arrays concluded that reducing the Si3N4 thickness from 250 nm to 500 nm reduces the torsional stiffness by a factor of approximately four. This is in good agreement with analytical and finite element models of the microshutters.

silicon nitride↗

DOE OSTI2016

Energy dissipation via acoustic emission in ductile crack initiation

In this article, we present a modeling approach to estimate the energy release due to ductile crack initiation in conjunction to the energy dissipation associated with the formation and propagation of transient stress waves typically referred to as acoustic emission. To achieve this goal, a ductile fracture problem is investigated computationally using the finite element method based on a compact tension geometry under Mode I loading conditions. To quantify the energy dissipation associated with acoustic emission, a crack increment is produced given a pre-determined notch size in a 3D cohesive-based extended finite element model. The computational modeling methodology consists of defining a damage initiation state from static simulations and linking such state to a dynamic formulation used to evaluate wave propagation and related energy redistribution effects. The model relies on a custom traction separation law constructed using full field deformation measurements obtained experimentally using the digital image correlation method. The amount of energy release due to the investigated first crack increment is evaluated through three different approaches both for verification purposes and to produce an estimate of the portion of the energy that radiates away from the crack source in the form of transient waves. The results presented herein propose an upper bound for the energy dissipation associated to acoustic emission, which could assist the interpretation and implementation of relevant nondestructive evaluation methods and the further enrichment of the understanding of effects associated with fracture.

42 ENGINEERING↗

DOE OSTI2025

Enhancing Post-Irradiation Examination (PIE) Efficiency with High-Throughput Experiments

Nuclear materials testing is essential for understanding changes in reactor environments, but traditional methods are costly and time-consuming. High-Throughput Experimentation (HTE) enables rapid screening and optimization of material properties by significantly increasing the number of specimens in the experiment. In this work, HTE methods were employed to irradiate novel materials at the Advanced Test Reactor (ATR) at Idaho National Laboratory. A total of 367 sub-sized tensile specimens were irradiated using the standard capsule design. To facilitate HTE, automated systems such as the Automated Mechanical Testing System were implemented for mechanical testing within hot cell environments, thereby reducing the need for manual interaction with hot cell manipulators and significantly lowering both the cost and duration of experiments. Digital image correlation (DIC) was used to measure displacement during mechanical testing, providing precise, non-contact measurement capabilities. The methodologies developed in this research will support the advancement of HTE techniques for future nuclear materials testing experiments at ATR. This approach allows for more efficient and cost-effective evaluation of new materials, ultimately leading to improved reactor performance, enhanced safety, and extended longevity within the nuclear industry.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

In Situ Local Measurement of Austenite Mechanical Stability and Transformation Behavior in Third-Generation Advanced High-Strength Steels

Austenite mechanical stability, i.e., retained austenite volume fraction (RAVF) variation with strain, and transformation behavior were investigated for two third generation advanced high strength steels (3GAHSS) under quasi-static uniaxial tension: a 1200 grade, two-phase medium Mn (10 wt%) TRIP steel, and a 980 grade, three-phase TRIP steel produced with a quenching and partitioning heat treatment. The Mn (10 wt%) TRIP steel deforms inhomogeneously via propagative instabilities (Lüders and Portevin Le Châtelier-like bands) while the 980 grade TRIP steel deforms homogenously up to necking. The dramatically different deformation behaviors of these steels required the development of a new in-situ experimental technique that couples volumetric synchrotron X-ray diffraction measurement of RAVF with surface strain measurement using stereo digital image correlation (DIC) over the beam impingement area. Measurement results with the new technique are compared with those from a more conventional approach wherein strains are measured over the entire gauge region while RAVF measurement is the same as that in the new technique. A determination is made as to the appropriateness of the different measurement techniques in measuring the transformation behaviors for steels with homogeneous and inhomogeneous deformation behaviors. Here, extension of the new in-situ technique to the measurement of austenite transformation under different deformation modes and to higher strain rates is discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

The effects of microstructure on deformation twinning in Mg WE43

The interplay between microstructure and deformation twinning in a WE43-T6 Mg alloy under uniaxial compression was investigated using a combination of scanning electron microscopy with digital image correlation (SEM-DIC) and crystal plasticity finite element (CPFE) simulation. To improve understanding of the statistical characteristics of deformation twin formation, microstructural effects were characterized in over 1000 grains through metrics including the nominal Schmid Factor, grain size, geometric compatibility factor (m'), residual Burgers vector, and the strain accommodated by neighboring grains. There was a strong correlation between the nominal Schmid Factor and both twin activation and variant selection, but this was not fully deterministic. Deformation twinning also exhibited a strong dependence on existing slip and twinning in the neighboring grain and on the m' value. Within the range of grain sizes present in this condition, grain size was determined to have minimal effect on deformation twinning. Finally, statistical analysis of CPFE simulations was used to further investigate microstructural effects on twinning, and qualitatively captured the effect of the nominal Schmid Factor.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Experimental and theoretical study of the restrained shrinkage cracking of early age well cement

The shrinkage cracking occurring in oil & gas well cement material is a major factor that reduces the cement sheath integrity and impairs the durability of an underground well. Shrinkage mainly takes place in the early hydration period of the cement, and the resulting restrained shrinkage cracking can form a leaking network for oil & gas or carbon dioxide stored in an underground reservoir. It is thus important to understand the early age behavior of well cement and the leaking pathway formation in the well. This study describes the application of the digital image correlation (DIC) method as a tool to measure the strain development and crack distributions of well cement in the lab during early phase changes. A theoretical model is presented to calculate the stress distribution built up in the cement sheath during early ages of well cement hydration, which helps to interpret the experimental observations and determine the major factors influencing the cracking sequences. This study presents the whole hydration – drying shrinkage – and cracking mechanism of early age well cement under restrained ring conditions experimentally and theoretically. Finally, the results offer useful insights on the key material and geometric parameters which control the fracture of a well cementing structure.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Deformation-induced spatiotemporal fluctuation, evolution and localization of strain fields in a bulk metallic glass

Deformation behavior and local strain evolutions upon loading and unloading of a bulk metallic glass (BMG) were systematically investigated by in situ digital image correlation (DIC). Distinct fluctuations and irreversible local strains were observed before the onset of macroscopic yielding. Statistical analysis shows that these fluctuations might be related to intrinsic structural heterogeneities, and that the evolution history and characteristics of local strain fields play an important role in the subsequent initiation of shear bands. Effects of sample size, pre-strain, and loading conditions were systematically analyzed in terms of the probability distributions of the resulting local strain fields. It is found that a higher degree of local shear strain heterogeneity corresponds to a more ductile stressestrain curve. Implications of these findings are discussed for the design of new materials.

36 MATERIALS SCIENCE↗

DOE OSTI2014

The Uniaxial Tensile Response of Porous and Microcracked Ceramic Materials

The uniaxial tensile stress-strain behavior of three porous ceramic materials was determined at ambient conditions. Test specimens in the form of thin beams were obtained from the walls of diesel particulate filter honeycombs and tested using a microtesting system. A digital image correlation technique was used to obtain full-field 2D in-plane surface displacement maps during tensile loading, and in turn, the 2D strains obtained from displacement fields were used to determine the Secant modulus, Young s modulus and initial Poisson s ratio of the three porous ceramic materials. Successive unloading-reloading experiments were performed at different levels of stress to decouple the linear elastic, anelastic and inelastic response in these materials. It was found that the stress-strain response of these materials was non-linear and that the degree of nonlinearity is related to the initial microcrack density and evolution of damage in the material.

anelasticity↗

DOE OSTI2024

Additively manufactured β-Ti5553 with laser powder bed fusion: Microstructures and mechanical properties of bulk and lattice parts

Ti5553 (Ti-5Al-5Mo-5V-3Cr wt%) is a titanium alloy widely used for its high strength-to-weight ratio and good formability at elevated temperatures. Unlike Ti-6Al-4V, Ti5553 does not undergo martensitic transformation, preventing cracking of brittle martensite upon rapid cooling. This makes it a strong candidate for additive manufacturing (AM), particularly laser powder bed fusion (L-PBF). L-PBF offers the unique opportunity to make fine lattice structures to reduce component weight. Despite the growing field of AM, there have been limited studies on L-PBF Ti5553 lattices and how their properties differ from the bulk. Here the present work addresses this knowledge gap by investigating microstructures and properties of L-PBF bulk and lattice parts and the effect of post L-PBF heat treatments. Electron microscopy and mechanical testing show that the high dislocation density formed during L-PBF increases bulk part’s yield strength by approximately 100 MPa compared to the conventional alloy. Digital image correlation during compression testing of octet truss lattices reveals a layer-by-layer failure mode. Compared to the bulk, the lattice contains copious ω nanoprecipitation, weaker <001> texture, smaller average grain sizes, and larger content of high-angle grain boundaries. These features elicit differences in Taylor factor distributions for the lattice depending on load direction, underlining challenges in predicting lattice mechanical response based on bulk properties. By examining the processing-structure-property relationships in the bulk and lattice, the present results delineate their microstructural and mechanical differences and establish a benchmark for the future design applications of L-PBF Ti5553.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Automated identification of deformation twin systems in Mg WE43 from SEM DIC

In this study, the application of machine learning and computer vision approaches to microscale deformation data for the automated identification of deformation twinning systems, and their associated twin area, is introduced. Deformation data was obtained during in-situ SEM compression testing of a WE43 Mg alloy using digital image correlation (DIC) modified for use with electron microscopy. A 5.7 mm × 3.4 mm area of interest was analyzed, generating ~100 million data points of deformation. Experimental twin trace directions were determined by applying k-means clustering, morphological thinning, and Hough transforms to the deformation data. The identification of deformation twinning was achieved by consideration of the twin trace direction, its strain value, and its evolution. The deformation map was divided into areas corresponding to individual active twin systems, enabling the analysis of microstructure dependence of deformation behavior and twinning activity. The performance of the proposed twinning identification approach was evaluated by accuracy, precision, and sensitivity metrics. The effect of the tuning parameters used in the algorithm on the performance is also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Investigation of the dynamic stress–strain response of compressible polymeric foam using a non-parametric analysis

Dynamic stress–strain response of rigid closed-cell polymeric foams is investigated in this work by subjecting high toughness polyurethane foam specimens to direct impact with different projectile velocities and quantifying their deformation response with high speed stereo-photography together with 3D digital image correlation. The measured transient displacement field developed in the specimens during high stain rate loading is used to calculate the transient axial acceleration field throughout the specimen. A simple mathematical formulation based on conservation of mass is also proposed to determine the local change of density in the specimen during deformation. By obtaining the full-field acceleration and density distributions, the inertia stresses at each point in the specimen are determined through a non-parametric analysis and superimposed on the stress magnitudes measured at specimen ends to obtain the full-field stress distribution. Furthermore, the process outlined above overcomes a major challenge in high strain rate experiments with low impedance polymeric foam specimens, i.e. the delayed equilibrium conditions can be quantified.

42 ENGINEERING↗