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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Utah FORGE: Fault Reactivation Through Fluid Injection Induced Seismicity Laboratory Experiments

Included are results from shear reactivation experiments on laboratory faults pre-loaded close to failure and reactivated by the injection of fluid into the fault. The sample comprises a single-inclined-fracture (SIF) transecting a cylindrical sample of Westerly granite. All experiments are conducted at ambient temperature and follow a similar protocol: (i) application of confining stresses (3MPa) on the fault fully saturated with DI water, (ii) shear-mobilization through the increase of axial loading at a constant displacement rate until a post-peak steady-state condition is reached, (iii) reduction of axial loading and related shear stress to a prescribed fraction of the peak steady-state frictional strength (typically 60% to 90%, representing intermediate to high magnitudes) and (iv), fault reactivation triggered by a stepwise increase of pore pressure on the fault in 0.1 MPa increments held constant for 1-5 minutes. Mechanical data from three ISCO pumps connected to a Temco pressure vessel measure axial, confining, and fault-related parameters, including fluid pressure (kPa), fluid flow rate (mL/min), and axial displacement (mm). See included code for initial data analysis and visualization for select experiments. Resource names represent experiment numbers found in the "Read Me" file, which describes each experimental setup and parameters.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

A Numerical Modeling Framework for Flocculation and Cohesive Sediment Transport in the Wave Bottom Boundary Layer

Flocculation, a critical process in coastal and estuarine systems, plays a significant role in sediment transport, nutrient cycling, and ecological health. This study develops a cohesive sediment transport modeling framework tailored to the wave bottom boundary layer under dilute and equilibrium conditions, explicitly incorporating flocculation effects via a Population Balance Equation (PBE). Using Direct Numerical Simulation, six baseline cases, each with a distinct sediment concentration profile resulting from a constant settling velocity and critical erosion shear stress, are generated to drive the PBE flocculation model for given floc yield strength and stickiness. Results reveal that flocculation significantly influences sediment concentration profiles promoting three distinct stages, well‐mixed, transition to lutocline, and well‐developed lutocline. At low concentrations with well‐mixed profiles, cohesive floc properties are less significant, and turbulence is a main flocculation driver. In contrast, as concentration increases, cohesive floc properties become crucial, facilitating lutocline formation. Here, the analysis also highlights limitations of depth‐averaged settling velocity as a parameterization. It is suitable for well‐mixed and transitional profiles but fails in well‐developed lutoclines, where empirical formulations that explicitly incorporate turbulent shear rate and sediment concentration better capture variability. This study underscores the necessity of incorporating flocculation effects into sediment transport models to enhance predictions of sediment dynamics in wave bottom boundary layers.

Penaloza‐Giraldo, Jorge A. [Oak Ridge National Lab↗
DOE OSTI2021

Hydro-mechanical measurements and x-ray imaging of sheared crystalline rock fractures from EGS Collab experiments 1 & 2

Measuring hydro-mechanical properties of natural fractures is a prerequisite for optimizing hydraulic stimulation design and well placement. We completed experiments to characterize shear on natural fractures in schist, amphibolite, and rhyolite specimens drilled from EGS Collab Project’s field sites at the Sanford Underground Research Facility (SURF) in South Dakota. A triaxial direct shear method and coupled x-ray imaging were used to perform hydroshearing and mechanical shearing at the site’s in-situ stress conditions. This produced simultaneous measurements of fracture and matrix strength, permeability, stress-dependent aperture, dilation, and friction strength. Our results identified that only a subset of the natural fractures was weak enough for hydroshearing. Generally, hydroshearing increases fracture permeability by a factor of 10 or more and the enhancement is retainable over time. However, the shear slip does not always result in permeability enhancement. High content of phyllosilicates was found to associate with exceptionally weak fractures that also exhibited poor or even negative enhancement after stimulation. Combining our measurements with site data, we can predict that most observable fractures at the two EGS Collab sites do not meet the criteria for hydroshearing before tensile opening. In some cases, the visible fractures are low permeability and as strong as the adjacent rock. To induce hydroshearing before tensile opening, injection must target known weak and favorably oriented fractures with confirmed pre-existing permeability.

58 GEOSCIENCES↗
DOE OSTI2022

Thixotropic spectra and Ashby-style charts for thixotropy

There is no universal model for thixotropy, and comparing thixotropic effects between different fluids is a subtle yet challenging problem. We introduce a generalized (model-insensitive) framework for comparing thixotropic properties based on thixotropic spectra. A superposition of exponential stress modes distributed over thixotropic time scales is used to quantify buildup and breakdown times and mode strengths in response to step-change input. This mathematical framework is tested with several experimental step-shear rate data on colloidal suspensions. Low-dimensional metrics based on moments of the distribution reveal characteristic average thixotropic properties, which are visualized on Ashby-style diagrams. This method outlines a framework for describing thixotropy across a diverse range of microstructures, supporting scientific studies as well as material selection for engineering design applications.

Mechanics↗
DOE OSTI2022

Switching from batch to continuous granulation: A case study of metoprolol succinate ER tablets

Continuous manufacturing (CM) has been used to produce several immediate release drug products. No extended-release (ER) product manufactured employing CM technology has been approved yet. Herein this study investigated the critical aspects of switching from the batch mode of high shear granulation to the continuous operation of twin-screw granulation for extended-release tablets. Metoprolol succinate ER tablets was used as a model ER formulation for this purpose. A central composite design (CCD) was employed to determine the effects of high shear granulator (HSG) parameters, namely impeller speed, granulation time, and binder liquid feeding rate, on the critical granulation characteristics important for product performance. These critical granulation characteristics served as a guide for switching from the batch processing to the continuous operation for achieving the same breaking strength and dissolution for this ER metoprolol tablets. The granulation time was the most critical factor affecting the bulk properties of granules which contributed to tablet dissolution. The higher density and lower compressibility of granules were attained at the longest granulation time of 5.4 min with the fastest liquid feeding rate of 75 g/min. The granules’ density was the primary factor negatively affecting the dissolution of metoprolol tablets. However, the breaking strength of tablets confounded the effect of granules density on metoprolol dissolution. Switching the processing parameters of high shear granulation to twin-screw granulation achieved similar dissolution profiles (F2 greater than 50). The screw speed was not found to affect bulk properties of granules. The root cause of granulation failures in twin-screw granulation, such as premature consolidation, excessive swelling, poor cohesion, inconsistent shearing effects, and formation of deformed agglomerates, were identified. In conclusion, the use of critical granulation characteristics through a performance-based approach of ER tablets facilitated the switching of manufacturing of an ER formulation form batch to continuous operation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Microstructure, Texture, and Strength Development during High-Pressure Torsion of CrMnFeCoNi High-Entropy Alloy

The equiatomic face-centered cubic high-entropy alloy CrMnFeCoNi was severely deformed at room and liquid nitrogen temperature by high-pressure torsion up to shear strains of about 170. Its microstructure was analyzed by X-ray line profile analysis and transmission electron microscopy and its texture by X-ray microdiffraction. Microhardness measurements, after severe plastic deformation, were done at room temperature. It is shown that at a shear strain of about 20, a steady state grain size of 24 nm, and a dislocation density of the order of 1016 m−2 is reached. The dislocations are mainly screw-type with low dipole character. Mechanical twinning at room temperature is replaced by a martensitic phase transformation at 77 K. The texture developed at room temperature is typical for sheared face-centered cubic nanocrystalline metals, but it is extremely weak and becomes almost random after high-pressure torsion at 77 K. The strength of the nanocrystalline material produced by high-pressure torsion at 77 K is lower than that produced at room temperature. The results are discussed in terms of different mechanisms of deformation, including dislocation generation and propagation, twinning, grain boundary sliding, and phase transformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Deformation behavior of metallic glass composites and plasticity accommodation at microstructural length-scales

Bulk metallic glass matrix composites represent a unique microstructural design strategy for overcoming the strength/ductility trade-off in structural alloys. Site-specific mechanical behavior of a Ti-based bulk metallic glass composite was evaluated at microstructural length-scale. The micro-pillars on the amorphous matrix showed on average a yield point of 1.9 GPa followed by serrated plastic deformation characteristic of shear banding. In contrast, micro-pillars on the crystalline dendritic phase showed a much lower yield strength of 0.72 GPa on average for the four different crystallographic orientations chosen, smooth plastic flow with no recognizable load burst, and stable strain-hardening after yield point. A number of micro-pillars were made at the interface between the glassy matrix and the crystalline dendrite. The mixed micro-pillars showed homogeneous deformation and greater plasticity which was attributed to their smaller stored elastic energy. Shear bands initiated in the amorphous matrix were arrested by the crystalline dendrite, which accommodated plasticity through slip bands and dislocations pile-ups. The interface remained intact after plastic deformation, with no observable signs of devitrification in the amorphous phase.

Bulk metallic glass matrix composite, Micro-pillar↗
DOE OSTI2022

High-Entropy Borides under Extreme Environment of Pressures and Temperatures

The high-entropy transition metal borides containing a random distribution of five or more constituent metallic elements offer novel opportunities in designing materials that show crystalline phase stability, high strength, and thermal oxidation resistance under extreme conditions. We present a comprehensive theoretical and experimental investigation of prototypical high-entropy boride (HEB) materials such as (Hf, Mo, Nb, Ta, Ti)B2 and (Hf, Mo, Nb, Ta, Zr)B2 under extreme environments of pressures and temperatures. The theoretical tools include modeling elastic properties by special quasi-random structures that predict a bulk modulus of 288 GPa and a shear modulus of 215 GPa at ambient conditions. HEB samples were synthesized under high pressures and high temperatures and studied to 9.5 GPa and 2273 K in a large-volume pressure cell. The thermal equation of state measurement yielded a bulk modulus of 276 GPa, in excellent agreement with theory. The measured compressive yield strength by radial X-ray diffraction technique in a diamond anvil cell was 28 GPa at a pressure of 65 GPa, which is a significant fraction of the shear modulus at high pressures. The high compressive strength and phase stability of this material under high pressures and high temperatures make it an ideal candidate for application as a structural material in nuclear and aerospace fields.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dislocation cross-slip in precipitation hardened Mg–Nd alloys

An integrated experimental characterization and molecular dynamics (MD) simulation approach was used to explore the dislocation-precipitate interactions in a dilute Magnesium–Neodymium (Mg–Nd) precipitation hardened alloy. In situ indentation in a transmission electron microscope (TEM) and postmortem TEM characterization of deformed samples and MD simulations revealed that basal < a > type dislocations interacted differently with β 1 (Mg 3 Nd) and β"(Mg 3-7 Nd) precipitates. For β" precipitates, the basal dislocations directly shear the precipitates. For β 1 precipitates, such shearing becomes much more difficult because it requires the creation of antiphase boundaries in the ordered lattice of β 1 precipitates. Screw dislocations were observed to cross-slip from basal to the prismatic plane, which could be parallel to the broad facet of β 1 precipitates. It is postulated that double cross-slip (basal to prismatic to basal) via the Hirsch mechanism may enable screw dislocations to overcome the β 1 precipitates. MD simulations also revealed that an edge dislocation is unable to bypass the precipitate via the generation of screw dislocation segments plus the double cross-slip mechanism. The edge dislocation can bow around the precipitate, and the segment that adopts a screw character can cross-slip to the prismatic plane but with increasing applied stress, cross-slips back to the original basal plane to continue glide via precipitate shearing. Finally, the implication of glide dislocation - β 1 -precipitate interaction mechanisms on the strength and ductility of β 1 precipitate dominant microstructures is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Collapse of helium-filled voids in extreme deformation: Dislocation mechanisms

The mechanisms responsible for the collapse of helium-filled bubbles during the passage of shock waves in monocrystalline copper are revealed. Both internal pressure (caused by pre-existing helium atoms) and bubble size are varied in molecular dynamics simulations to understand the atomistic scale deformation as they are subjected to shock compression at pressures of 48, 123, and 170 GPa, corresponding to particle velocities of 1.0, 2.0, and 2.5 km/s. Both empty and helium filled bubbles serve as dislocation sources, generating intense, localized plastic regions. There are distinct differences in the collapse of empty voids compared to He-filled bubbles, the former requiring less stress and generating a greater density of dislocations for a given shock strength. Additionally, a generalized model for dislocation emission is proposed, where the inclusion of shear stress generated by the helium bubble increases the critical stress to generate dislocations at the defect surface, demonstrating the change in plastic deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The formation and evolution of Ni 2 Cr precipitates in Ni–Cr model alloys as a function of stoichiometry characterized by synchrotron x-ray diffraction

Ni-based alloys containing significant amounts of Cr, may precipitate new phases during long-term service at elevated temperatures. In Ni–Cr model alloys, the formation of Ni 2 Cr has been found to impact the material properties, including the strength and ductility after isothermal aging below the critical temperature of 590°C. In this work, we quantify the formation and evolution of long-range ordering in four Ni–Cr binary model alloys (Ni/Cr = 1.8, 2.0, 2.2, 2.4) after isothermal aging up to 10,000h at temperatures between 373 and 475°C. The alloys were characterized by hardness testing and synchrotron-based x-ray diffraction to quantify the impact of Ni 2 Cr phase fraction and precipitate size on mechanical properties. After 500h of isothermal aging, the formation of Ni 2 Cr was detected in all four alloys at 475°C. In the stochiometric alloy samples (Ni/Cr = 2.0), the formation of Ni 2 Cr was found after 500 and 3000h aging at 418 and 373°C, respectively. We found that the matrix lattice contraction and Ni 2 Cr phase fraction both saturate after early aging times. This is in stark contrast to the hardness and Ni 2 Cr precipitate size that both continue to increase with increasing aging time. Our results highlight that changes in hardness correlate linearly with Ni 2 Cr precipitate size rather than phase fraction. This important structure-property relationship can potentially help define Ni–Cr-based component lifetimes directly through an understanding of how Ni 2 Cr formation impacts strength and ductility. Here, we find that a precipitation hardening model for critical resolved shear stress with weakly coupled dislocations shows good agreement with the material property changes quantified from experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High-rate strength response of tantalum from dynamic hole closure experiments

The science and engineering communities have significant interest in experimental platforms to evaluate and improve models for dynamic material deformation. While well-developed platforms exist, there are still gaps to fill for strain and strain rate conditions accessed during impact and other high-rate loading scenarios. To fill one such gap for strength measurements, a platform was recently developed that accesses high strain rate (≥ 10 5 /s) and large strain (≥ 50%) conditions by measuring the transient closure of a cylindrical hole using in situ x-ray imaging. In the work reported here, further refinement of the platform is performed to reduce the potential effects of porosity and anelasticity on the measurement. This helps us to isolate the strength effects that are the focus of the experiment. The updated experimental configuration employs a two-layer flyer design and elongated target to reduce the magnitude of the tensile excursions associated with rarefaction wave interactions. This allows for a more direct assessment of strength models commonly used for dynamic simulations of metals. Here we apply the new technique to well-characterized tantalum material, allowing for a robust connection to other experimental techniques. Deformation localization can be a concern in large strain experiments, and to help inform future use of the experimental platform, we use simulations with a sub-zone treatment of shear banding to explore potential localization behavior. Here we develop and utilize an experimental configuration with improved isolation of strength effects that can be applied to an expanded range of materials.

42 ENGINEERING↗
DOE OSTI2023

Performance of hybrid Innegra-carbon fiber composites

Abstract In this work material synergy with high stiffness carbon fiber with ductile high strength polypropylene fiber (Innegra S), (referred to as Innegra, herein) have been evaluated in a range of laminate designs. Both woven and discontinuous carbon fiber have been considered. The discontinuous fibers are based on three-dimensional deposition (3DEP) (referred to as 3DEP, herein) carbon fiber preform process. Eleven (11) variants of Innegra-carbon fiber hybrid laminates were investigated for tensile, flexure, compression, in-plane shear and low velocity impact response. The effect of position of Innegra within the laminate was studied and found to influence strength and stiffness properties. In terms of overall trends, Innegra provides upward of 18% improvement in strain (ductility) to the composite and eliminates brittle fracture of carbon fiber. The moduli trends follow the proportionality of Innegra fiber to carbon fiber plies. However, the strength is controlled by the interface between Innegra and carbon fiber. The primary failure mode in tension and compression is via onset of debonding between Innegra and carbon fiber. The 3DEP carbon fiber constituents provided highest values of in-plane shear indicating that three-dimensional (3D) network of carbon fiber provides higher shear resistance. The Innegra intensive variants exhibited superior energy absorption under low velocity impact, at energy levels 15–60 J. This work provides insight for designers to incorporate Innegra and carbon fiber hybrids in composite structures.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Recycling of Titanium Scrap by Shear Assisted Processing and Extrusion (ShAPE)

Titanium and its alloys are used in the aviation and automobile industries due to their remarkable strength to weight ratio, but, commonly, machining loss is high with ~90 wt.% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, reducing or even eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting rotation rate and feed rate, to process the billets near 1000°C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of recycling Ti-6Al-4V scrap directly into extruded wire.

36 MATERIALS SCIENCE↗
DOE OSTI2025

On resistive interchange, double tearing, and resonant and non-resonant infernal modes in spherical tokamak negative central shear discharges

We examine the linear and nonlinear stability of a sequence of reversed shear NSTX equilibria with the same toroidal current density and pressure profile but with different toroidal field strengths. All equilibria have two q = 2 surfaces and have q > 1 everywhere. For this sequence, which all have β P ∼ 0.5, as the minimum value of q decreases below about 1.4, the localized resistive interchange criterion is strongly violated, and the unstable mode with toroidal mode number n=1 changes its dominant poloidal mode number m from a (m,n)=(2,1) double tearing mode to a non-resonant (1,1) infernal mode. This (1,1) mode nonlinearly flattens both the current density and the pressure near the magnetic axis. The higher-n unstable modes are all resistive infernal modes localized around the surface where q has a minimum and the magnetic shear vanishes. They generally saturate nonlinearly at low amplitude but can cause magnetic surface breakup near the axis.

Spitzer resistivity↗
DOE OSTI2025

Current activated reactive ultrafast joining (CARUJ) of silicon carbide

In this work we propose and demonstrate a novel approach for rapid fabrication of ceramic-ceramic joint assemblies, using sintered Silicon Carbide (SiC) as an initial example. Current Activated Reactive Ultrafast Joining (CARUJ) utilizes resistive heating of carbon-based materials to apply localized heat at or around the joint zone at heating rates of 101– 103 °C/min. CARUJ is used to fabricate SiC-SiC joints with a Si-SiC interface using minimal pressure (1–2 MPa) at time scales considerably shorter (several minutes opposed to hours) than conventional approaches for similar systems. The reaction of an interfacial precursor based on elemental silicon and carbon leads to in-situ SiC formation to produce a continuous and dense bond in a single step. Measured average joint strengths of roughly 15 MPa are achieved when tested in single lap offset (SLO) compressive shear. Optional additions of refractory metals such as molybdenum can be utilized to introduce secondary inclusions such as MoSi 2 within the joint interface. We further demonstrate SiC-SiC joining using Active Brazing Alloys (ABA) and proof of concept joining of tubular geometries. The localized and rapid heat application realizes a versatile material joining technique that could be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Factors controlling injection-induced rupture of intersecting faults during geological sequestration of CO 2

This study addresses coupled multiphase fluid flow and geomechanics effects on potential fault activation associated with subsurface CO 2 injection around intersecting faults. An enhanced fault-representation model is used to capture geomechanical responses of two intersecting faults with finite length during CO 2 injection. The faults are embedded in a strike-slip stress regime of a caprock-reservoir-basement system with the faults represented by zero-thickness interfaces with adjacent finite-thickness damage zones. A sensitivity analysis is conducted to study the effect of fault permeability, slip-weakening behavior, well location relative to the orientation of faults, and well placement (the number and location of injection wells). Five metrics (pressure, CO 2 plume, shear state on the fault, as well as shear displacement and stress path at selected fault monitoring points) are selected to assess CO 2 migration and reactivation of intersecting faults. The results show that induced ruptures are favored by low permeability faults due to high pressure buildup and by slip-weakening behavior resulting from fault strength reduction. The location of one injection well relative to fault orientation determines the magnitude of changes in effective normal stress and shear stress, affecting the location of induced ruptures. Well placement (two injection wells used in the paper) dominates pressure diffusion around the intersection and tips of faults. This redistributes changes in effective normal stress caused by each injection well, influencing the spatial distribution of ruptures along faults. A larger injection volume induces far-field ruptures that are controlled by stress transfer within the injection layer. The findings presented here can provide valuable insights into engineering operations for a long-term, safe, and reliable geologic CO 2 storage.

Fault permeability↗
DOE OSTI2022

Precursory Off-Fault Deformation in Restraining and Releasing Step Overs: Insights From Discrete Element Method Models

Accelerating geophysical activity is detected preceding some, but not all, large earthquakes. This observation may indicate that no precursors occur before some earthquakes, or that the instrumentation lacks the required sensitivity. Here, to aid crustal monitoring efforts, we use discrete element method models to identify the locations and styles of deformation that may provide useful information about approaching fault reactivation. We model the reactivation of two healed rough faults in a variety of step over configurations, embedded in a host rock with varying amounts of damage subject to shear velocity loading parallel to the faults. Both the fault geometry and ratio of fault to host rock strength control the amount of off-fault deformation. Consistent with field observations, models with larger steps and more preexisting host rock damage produce higher amounts of off-fault deformation. We assess the size of the continuous regions of high velocities and strains to compare the value of the precursory information of each velocity and strain component. Comparing the three components of the velocity vector suggests that the fault-parallel velocity produces the largest and most temporally continuous regions of elevated velocity. The size of these regions increases toward failure, indicating the usefulness of tracking this component. Comparing the volumetric and shear components of the three-dimensional strain tensor suggests that during most of the interseismic period, the shear strain provides more information about approaching fault slip than the volumetric strain. However, in the days and months preceding fault reactivation, both the shear and volumetric strains provide similarly valuable information.

58 GEOSCIENCES↗