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At least 253 records · Page 14

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NASA NTRS1997

Fiber Contraction Approaches for Improving CMC Proportional Limit

The fact that the service life of ceramic matrix composites (CMC) decreases dramatically for stresses above the CMC proportional limit has triggered a variety of research activities to develop microstructural approaches that can significantly improve this limit. As discussed in a previous report, both local and global approaches exist for hindering the propagation of cracks through the CMC matrix, the physical source for the proportional limit. Local approaches include: (1) minimizing fiber diameter and matrix modulus; (2) maximizing fiber volume fraction, fiber modulus, and matrix toughness; and (3) optimizing fiber-matrix interfacial shear strength; all of which should reduce the stress concentration at the tip of cracks pre existing or created in the matrix during CMC service. Global approaches, as with pre-stressed concrete, center on seeking mechanisms for utilizing the reinforcing fiber to subject the matrix to in-situ compressive stresses which will remain stable during CMC service. Demonstrated CMC examples for the viability of this residual stress approach are based on strain mismatches between the fiber and matrix in their free states, such as, thermal expansion mismatch and creep mismatch. However, these particular mismatch approaches are application limited in that the residual stresses from expansion mismatch are optimum only at low CMC service temperatures and the residual stresses from creep mismatch are typically unidirectional and difficult to implement in complex-shaped CMC.

DiCarlo, James A.↗

DOE OSTI2025

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

36 MATERIALS SCIENCE↗

NASA NTRS2011

Laser Peening Effects on Friction Stir Welding

Friction Stir Welding (FSW) is a welding technique that uses frictional heating combined with forging pressure to produce high strength bonds. It is attractive for aerospace applications. Although residual stresses in FSW are generally lower when compared to conventional fusion welds, recent work has shown that significant tensile residual stresses can be present in the weld after fabrication. Therefore, laser shock peening was investigated as a means of moderating the tensile residual stresses produced during welding. This slide presentation reviews the effect of Laser Peening on the weld, in tensile strength, strain, surface roughness, microhardness, surface wear/friction, and fatigue crack growth rates. The study concluded that the laser peening process can result in considerable improvement to crack initiaion, propagation and mechanical properties in FSW.

Hatamleh, Omar↗

NASA NTRSDate not supplied

Process Modeling of Woven Textiles

Woven polymer matrix composites offer numerous advantages over traditional unidirectional laminates. Processing conditions affect residual stress that builds up during manufacturing. This work proposes the analysis of three curing parameters on the local residual stress distribution of a plain weave textile architecture, including chemical shrinkage, the temperature cool down, and the evolution of matrix properties as a function of curing. Virtual curing is applied to the inter-tow matrix material of the plain weave Repeating Unit Cell (RUC) modeled in TexGen. Curing is implemented through user-written subroutines within the commercial software suite Abaqus. Results from process modeling are compared with a linear-elastic thermal cool down in Abaqus. A boundary conditions study is also conducted to compare the residual stress build up predicted by Flat(FBCs) and Periodic Boundary Conditions (PBCs). Preliminary results indicate that a thermal cool down over-estimates the end-of-cure stresses in the matrix. Process modeling is conducted with and without chemical shrinkage, then compared with a thermal cool down. Results show that 11.32% of the final stress state is due to chemical shrinkage. Material property evolution during curing also has a non-negligible effect on the end stress.

woven composites↗

NASA NTRS2003

Lifetime Predictions of a Titanium Silicate Glass with Machined Flaws

A dynamic fatigue study was performed on a Titanium Silicate glass to assess its susceptibility to delayed failure and to compare the results with those of a previous study. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions. The material strength and lifetime was seen to increase due to the removal of residual stress through grinding and polishing. Influence on time-to-failure is addressed for the case with and without residual stress present. Titanium silicate glass otherwise known as ultra-low expansion (ULE)* glass is a candidate for use in applications requiring low thermal expansion characteristics such as telescope mirrors. The Hubble Space Telescope s primary mirror was manufactured from ULE glass. ULE contains 7.5% titanium dioxide which in combination with silica results in a homogenous glass with a linear expansion coefficient near zero. delayed failure . This previous study was based on a 230/270 grit surface. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing the material with successively smaller grinding media. This results in an increase in strength of the optic during the grinding and polishing sequence. Thus, a second study was undertaken using samples with a surface finish typically achieved for mirror elements, to observe the effects of surface finishing on the time-to-failure predictions. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure, most likely due to stress corrosion, which can significantly shorten lifetime. Fortunately, a theory based on fracture mechanics has been developed enabling lifetime predictions to be made for brittle materials susceptible to delayed failure. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct a time-to-failure diagram for polished ULE glass.

Tucker, Dennis S.↗

NASA NTRS1989

Thermoelastic micromechanical stresses associated with a large alpha-silicon carbide grain in a polycrystalline beta-silicon carbide matrix

The thermoelastic micromechanical stresses associated with a single large hexagonal alpha-SiC grain within a fine-grain-size cubic (3C) beta-SiC matrix were calculated. The naturally occurring residual stresses which are created during cooling from the processing temperatures and the effects of superimposed applied external stresses are both considered. A significant effect of the shape or geometry of the alpha-SiC grain is revealed, with the largest residual stresses associated with the naturally occurring tabular or platelet structure. The stresses are compared with the published strength results for these materials, which suggests that the residual stresses assume a significant role in the strength reduction that is observed.

Li, Zhuang↗

NASA NTRS1990

Large-eddy simulation of transitional channel flow

A large-eddy simulation (LES) of transition in plane channel flow was carried out. The LES results were compared with those of a fine direct numerical simulation (DNS), and with those of a coarse DNS that uses the same mesh as the LES, but does not use a residual stress model. While at the early stages of transition, LES and coarse DNS give the same results: the presence of the residual stress model was found to be necessary to predict accurately mean velocity and Reynolds stress profiles during the late stages of transition (after the second spike stage). The evolution of single Fourier modes is also predicted more accurately by the LES than by the DNS. As small scales are generated, the dissipative character of the residual stress starts to reproduce correctly the energy cascade. As transition progresses, the flow approaches its fully developed turbulent state, the subgrid scales tend towards equilibrium, and the model becomes more accurate.

Piomelli, Ugo↗

NASA NTRS1987

Comparison of measured temperatures, thermal stresses and creep residues with predictions on a built-up titanium structure

Temperature, thermal stresses, and residual creep stresses were studied by comparing laboratory values measured on a built-up titanium structure with values calculated from finite-element models. Several such models were used to examine the relationship between computational thermal stresses and thermal stresses measured on a built-up structure. Element suitability, element density, and computational temperature discrepancies were studied to determine their impact on measured and calculated thermal stress. The optimum number of elements is established from a balance between element density and suitable safety margins, such that the answer is acceptably safe yet is economical from a computational viewpoint. It is noted that situations exist where relatively small excursions of calculated temperatures from measured values result in far more than proportional increases in thermal stress values. Measured residual stresses due to creep significantly exceeded the values computed by the piecewise linear elastic strain analogy approach. The most important element in the computation is the correct definition of the creep law. Computational methodology advances in predicting residual stresses due to creep require significantly more viscoelastic material characterization.

Jenkins, Jerald M.↗

DOE OSTI2025

Multiplexing Focusing Analyzer for Efficient Stress-Strain Measurements

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 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 propose to design and demonstrate novel diffractive optical device, which will enable very efficient residual stress neutron diffractometers. The proposed device will be a multi-foil analyzer, where each foil is constructed of focusing bent single crystals of Si. Such device will enable polychromatic residual stress neutron diffraction. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast measurements for determining residual stress tensors, raster large samples or screen multiple samples. Commercial Applications and Other Benefits The outcome of this project would be the demonstration of commercial devices, novel neutron optical components, which could be utilized to improve the performance of existing instruments or build novel neutron scattering instruments at DOE neutron facilities and commercial laboratory neutron sources. These new devices will widen the scope of research conducted using neutrons and enable measurements not feasible at present. 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 ↗

NASA NTRS2002

Effects of Thermomechanical History on the Tensile Behavior of Nitinol Ribbon

Shape memory alloys (SMAs) have enormous potential for a wide variety of applications. A large body of work exists on the characterization of the microstructure and stress-strain behavior of these alloys, Nitinol (NiTi) in particular. However, many attributes of these materials are yet to be fully understood. Previous work at NASA Langley Research Center (LaRC) has included fabrication of hybrid composite specimens with embedded Nitinol actuators and modeling of their thermomechanical behavior. An intensive characterization effort has been undertaken to facilitate fundamental understanding of this alloy and to promote implementation of Nitinol in aerospace applications. Previous work revealed attributes of the Nitinol ribbon that were not easily rationalized with existing data in the literature. In particular, tensile behavior at ambient temperature showed significant dependence on the thermomechanical history prior to testing. The present work is focused on characterizing differences in the microstructure of Nitinol ribbons exposed to four different thermomechanical histories and correlation of the microstructure with tensile properties. Differential scanning calorimetry (DSC) and x-ray diffraction (XRD) analysis were employed to rationalize the microstructures present after exposure to various thermomechanical histories. Three of the Nitinol ribbon conditions were reversible upon heating (in the DSC) through the reverse transformation temperature (A(sub f) to transform the microstructure to austenite. However, the prior thermomechanical conditioning for the Nitinol ribbon that reflected the entire fabrication procedure (4% thermal cycle condition) was found to have an irreversible effect on the microstructure, as it remained unchanged after repeated complete thermal cycles. Tensile tests were conducted to determine the effect of prior thermomechancal conditioning on both the tensile behavior of the Nitinol ribbons and the stress state of the microstructure. The stress-strain behavior of the Nitinol actuators appears to be governed by the interplay between two major variables: namely, microstructural constituents such as the R-phase and the martensite; and the stress state of these constituents (whether twinned with low residual stresses, or detwinned with high residual stresses). The most significant difference in the stress-strain behavior of the four conditions, the critical stress required to achieve an initial stress plateau, was found to depend on both the amount and stress state (twinned or detwinned) of R-phase present in the initial microstructure. Thus, the effect of prior thermomechanical processing is critical to the resulting tensile behavior of the Nitinol actuator. For numerical modeling inputs one must take into account the entire fabrication process on the Nitinol actuator.

Lach, Cynthia L.↗

NASA NTRS1982

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.↗

DOE OSTI2025

XFEM Development for Modeling Crack Growth in Prototypical Welded Components

Nuclear power plant components are subjected to harsh operating environments that can lead to multiple degradation mechanisms in which fracture can play a prominent role. Predicting crack growth is important for assessing the integrity of welded components. The extended finite element method (XFEM) is an important tool for modeling such crack growth, and XFEM capabilities have been developed within the MOOSE framework. This report documents work in the MOOSE XFEM module to model fractures in three-dimensional representations of components using a topologically two-dimensional mesh to define cutting planes. Crack growth algorithms have been implemented to evolve the cutting mesh based on equations for stress corrosion cracking. Additionally, several usability and robustness improvements have been developed to enable three-dimensional fracture simulations. The cutting algorithms were demonstrated on a three-dimensional model of a prototypical reactor component undergoing stress corrosion cracking driven by idealized weld residual stresses. This is an incremental step toward using this capability to model more complex components with residual stresses computed through welding process simulations.

42 - ENGINEERING↗

DOE OSTI2025

Development of a thermal creep model for aluminum alloy 6061 cladding in U-10Mo monolithic fuel plates

Plate-type fuel elements consisting of a high-density, low-enriched uranium (LEU) U–10Mo-based fuel foil encapsulated in an aluminum alloy (AA) cladding are fabricated using the hot isostatic pressing (HIP) technique. During the HIP process, the fuel plate system is heated to 560 °C, then cooled to room temperature. This heat cycle significantly affects the mechanical properties of the aluminum cladding, and experimental investigations have shown that, post-HIP bonding, the mechanical properties of the aluminum cladding transition from those of AA 6061-T6 to something closer to the O temper. More specifically, the ultimate strength of the cladding decreases while its ductility increases, making it challenging to capture the changes in mechanical behavior and material properties. Understanding the residual stresses generated during the HIP process is critical for assessing the fuel plate’s integrity under various temperature, pressure, and irradiation. To simulate the HIP bonding process, the elastic, plastic, and thermal properties of the cladding are assumed to be similar to those of AA 6061-O temper. However, the primary challenge lies in the lack of available data for the creep model of the AA 6061 cladding during this transient process of HIP. The present study focuses on developing a computational model that predicts the creep behavior of the aluminum cladding in the fuel plates during the HIP process, as cladding creep significantly influences the residual stresses generated in U-10Mo fuel plates during HIP fabrication. Furthermore, as HIP bonding occurs at high temperatures that are nearing the melting point of aluminum, the present work considered a temperature-dependent Arrhenius-type creep model. In particular, a hyperbolic sine creep model is employed to estimate the creep properties of the as-fabricated aluminum cladding. In conclusion, the residual stresses predicted in the U-10Mo fuel when using the newly calibrated creep model closely align with the experimental measurements, validating the model’s accuracy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2003

The Effect of Tungsten and Niobium on the Stress Relaxation Rates of Disk Alloy CH98

Gas turbine engines for future subsonic transports will probably have higher pressure ratios which will require nickel-base superalloy disks with 1300 to 1400 F temperature capability. Several advanced disk alloys are being developed to fill this need. One of these, CH98, is a promising candidate for gas turbine engines and is being studied in NASA s Advanced Subsonic Technology (AST) program. For large disks, residual stresses generated during quenching from solution heat treatment are often reduced by a stabilization heat treatment, in which the disk is heated to 1500 to 1600 F for several hours followed by a static air cool. The reduction in residual stress levels lessens distortion during machining of disks. However, previous work on CH98 has indicated that stabilization treatments decrease creep capability. Additions of the refractory elements tungsten and niobium improve tensile and creep properties after stabilization, while maintaining good crack growth resistance at elevated temperatures. As the additions of refractory elements increase creep capability, they might also effect stress relaxation rates and therefore the reduction in residual stress levels obtained for a given stabilization treatment. To answer this question, the stress relaxation rates of CH98 with and without tungsten and niobium additions are compared in this paper for temperatures and times generally employed in stabilization treatments on modern disk alloys.

Gayda, John↗

NASA NTRS1992

Mechanical properties of 3C silicon carbide

The residual stress and Young's modulus of 3C silicon carbide (SiC) epitaxial films deposited on silicon substrates were measured by load-deflection measurements using suspended SiC diaphragms fabricated with silicon micromachining techniques. The film's residual stress was tensile and averaged 274 MPa while the in-plane Young's modulus averaged 394 GPa. In addition, the bending moment due to the residual stress variation through the thickness of the film was determined by measuring the deflection of free-standing 3C-SiC cantilever beams. The bending moment was in the range of 2.6 x 10 exp -8 -4.2 x 10 exp-8 N m.

Tong, Lijun↗

NASA NTRS1974

Thermal stresses in chemically hardening elastic media with application to the molding process

A method has been formulated for the determination of thermal stresses in materials which harden in the presence of an exothermic chemical reaction. Hardening is described by the transformation of the material from an inviscid liquid-like state into an elastic solid, where intermediate states consist of a mixture of the two, in a ratio which is determined by the degree of chemical reaction. The method is illustrated in terms of an infinite slab cast between two rigid mold surfaces. It is found that the stress component normal to the slab surfaces vanishes in the residual state, so that removal of the slab from the mold leaves the remaining residual stress unchanged. On the other hand, the residual stress component parallel to the slab surfaces does not vanish. Its distribution is described as a function of the parameters of the hardening process.

Levitsky, M.↗

NASA NTRSDate not supplied

Icing Formation Strains on Airfoil Skin

Aircraft icing has long presented a safety hazard to the aerospace industry. One problem inherent to aircraft icing is predicting the adhesive properties of the ice-aircraft interface; values commonly reported span multiple orders of magnitude, making shedding prediction and surface evaluation difficult. An effort has been undertaken at the NASA Glenn Research Center to understand the cause of the scatter in the data. Geometry dependencies, variation in testing procedures, and residual stresses in ice samples have previously been identified as significant contributors to the problem. Residual stresses were singled out for this study, which investigated the strains at the leading edge of a Common Research Model (CRM) wind tunnel model in the NASA Glenn Icing Research Tunnel. Sprays were conducted at a particle size median volumetric diameter (MVD) of 20 µm, with liquid water contents (LWC) spanning from 0.4 to 3.0 g/m3. Total temperatures were varied between 0 and -25 °C, and test section velocity between 51 and 118 m/s. The leading edge was instrumented with custom strain gages, resistance temperature detectors (RTDs), optical fibers, and a pressure mat. Results indicate Δ strains, which were the difference between recorded strains and those predicted from isotropic thermal expansion of aluminum, below -400 µε with consistent patterns of strain across a wide variety of tunnel conditions. Isotropic, linear elastic finite element analysis (FEA) was conducted by varying the temperature of simplified airfoil and ice geometries, producing similar strains to those observed in testing. This allowed induced stresses to be predicted. Predicted stresses were above the expected tensile strength for ice, and suggest a source for previously observed cracking in tunnel ice.

Ice Adhesion↗