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At least 253 records · Page 14

Characterize traction–separation relation and interfacial imperfections by data-driven machine learning models

Abstract Interfacial mechanical properties are important in composite materials and their applications, including vehicle structures, soft robotics, and aerospace. Determination of traction–separation (T–S) relations at interfaces in composites can lead to evaluations of structural reliability, mechanical robustness, and failures criteria. Accurate measurements on T–S relations remain challenging, since the interface interaction generally happens at microscale. With the emergence of machine learning (ML), data-driven model becomes an efficient method to predict the interfacial behaviors of composite materials and establish their mechanical models. Here, we combine ML, finite element analysis (FEA), and empirical experiments to develop data-driven models that characterize interfacial mechanical properties precisely. Specifically, eXtreme Gradient Boosting (XGBoost) multi-output regressions and classifier models are harnessed to investigate T–S relations and identify the imperfection locations at interface, respectively. The ML models are trained by macroscale force–displacement curves, which can be obtained from FEA and standard mechanical tests. The results show accurate predictions of T–S relations ( R 2 = 0.988) and identification of imperfection locations with 81% accuracy. Our models are experimentally validated by 3D printed double cantilever beam specimens from different materials. Furthermore, we provide a code package containing trained ML models, allowing other researchers to establish T–S relations for different material interfaces.

97 MATHEMATICS AND COMPUTING↗

Failure Diameter of PBX 9502: Simulations with the SURFplus model

SURFplus is a reactive burn model for high explosives aimed at modelling shock initiation and propagation of detonation waves. It utilizes the SURF model for the fast hot-spot reaction plus a slow reaction for the energy released by carbon clustering. A feature of the SURF model is that there is a partially decoupling between burn rate parameters and detonation wave properties. Previously, parameters for PBX 9502 that control shock ini- tiation had been calibrated to Pop plot data (distance-of-run to detonation as a function of shock pressure initiating the detonation). Here burn rate parameters for the high pres- sure regime are adjusted to t the failure diameter and the limiting detonation speed just above the failure diameter. Simulated results are shown for an uncon ned rate stick when the 9502 diameter is slightly above and slightly below the failure diameter. Just above the failure diameter, in the rest frame of the detonation wave, the front is sonic at the PBX/air interface. As a consequence, the lead shock in the neighborhood of the interface is supported by the detonation pressure in the interior of the explosive rather than the reaction immediately behind the front. In the interior, the sonic point occurs near the end of the fast hot-spot reaction. Consequently, the slow carbon clustering reaction can not a ect the failure diameter. Below the failure diameter, the radial extent of the detonation front decreases starting from the PBX/air interface. That is, the failure starts at the PBX boundary and propagates inward to the axis of the rate stick.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Fracture mechanics approach to TRISO fuel particle failure analysis

Weibull stress-based methods for failure probability assessment have been developed and analyzed to assess the integrity of tristructural isotropic (TRISO) fuel particles during fuel life cycles and accident operating conditions. While simple, these methods entail a number of drawbacks when stress concentrates near crack tips, including finite element mesh size dependency when the Weibull stress is averaged over the finite element domain. Fracture mechanics approaches involving the use of interaction integrals eliminate this lack of mesh convergence and produce consistent fracture predictions. In this work, we use an interaction integral approach to computing stress intensity factors for a crack in the inner pyrolytic carbon layer perpendicular to the silicon carbide layer, which is simplified representation of a failure mode in TRISO particles. Further, the interface between these two TRISO layers has been shown to become porous, which we simulate by considering a transition of mechanical properties over such porous length, i.e. the layers are modeled as a functionally graded material. Aspects such as porosity and thermal and irradiation eigenstrains are considered in computing the stress intensity factor from a fracture mechanics approach and compared with the known Weibull stress failure approach. The methodology introduced in this paper enables a more general fracture probability assessment in TRISO particles and eliminates the need to identify best suited parameters when using local or averaged stress-based failure criterion. Finally, the numerical sensitivity studies show how parameters such as the porous transition zone length, the material stiffness, and creep affect the probability of TRISO fuel particle failure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Heterogeneous creep deformation in Dissimilar Metal Welds (DMWs)

Dissimilar Metal Welds (DMWs) made between ferritic low alloy steels and austenitic alloys are widely used in high temperature components of nuclear and fossil energy power plants. Literature shows that these bimetallic welds fail prematurely by creep mechanism close to the interface of the ferritic (BCC) and austenitic regions (FCC), with lifetimes much less than the creep lives of both materials. These creep failures are associated with cavity formation close to BCC/FCC interfaces. However, the spatial and temporal variations of creep strain rates in these DMWs have not been measured. In this research, DMW coupons were fabricated between 2.25Cr-1Mo steel and Alloy 800 H base material using a Ni base Inconel weld consumable. These samples were aged at 600 °C for 2000 h and 4000 h to induce two different sizes and distributions of Type I interfacial carbides and further subjected to a short term (~1 month) creep testing. Here, surface strains were measured with Digital Image Correlation (DIC) technique to extract local creep strain rates. In both samples, creep strain concentration occurred in the BCC matrix. The location of creep strain concentration from the BCC/FCC interface, changed from 5 µm (2000 h aged condition) to 400 µm (4000 h aged condition) depending on the initial carbide distributions in these regions.

36 MATERIALS SCIENCE↗

Actuator digital interface unit (AIU)

Alternate versions of the actuator interface unit are presented. One alternate is a dual-failure immune configuration which feeds a look-and-switch dual-failure immune hydraulic system. The other alternate is a single-failure immune configuration which feeds a majority voting hydraulic system. Both systems communicate with the data bus through data terminals dedicated to each user subsystem. Both operational control data and configuration control information are processed in and out of the subsystem via the data terminal which yields the actuator interface subsystem, self-managing within its failure immunity capability.

Source record↗

Key Durability Issues with Mullite-Based Environmental Barrier Coatings for Si-Based Ceramics

Plasma-sprayed mullite (3Al2O3 central dot 2SiO2) and mullite/yttria-stabilized-zirconia (YSZ) dual layer coatings have been developed to protect silicon-based ceramics from environmental attack. Mullite-based coating systems show excellent durability in air. However, in combustion environments, corrosive species such as molten salt or water vapor penetrate through cracks in the coating and attack the Si-based ceramics along the interface, Thus modification of the coating system for enhanced crack-resistance is necessary for long-term durability in combustion environments. Other key durability issues include interfacial contamination and coating/substrate bonding. Interfacial contamination leads to enhanced oxidation and interfacial pore formation, while weak coating/substrate bonding leads to rapid attack of the interface by corrosive species, both of which can cause premature failure of the coating. Interfacial contamination can be minimized by limiting impurities in coating and substrate materials. The interface may be modified to improve the coating/substrate bond.

Lee, Kang N.↗

Uncertainty quantification for competing failure mechanisms in unidirectionally reinforced carbon–carbon composites

Microstructure-informed finite element models play a key role in the carbon–carbon composite design process. Variability in manufacturing process parameters and experimental limitations introduce model parameter uncertainty. This study quantifies the effect of model parameter uncertainty on transverse tensile fracture behavior and proposes a methodology to predict the failure mode based on competing microscale damage mechanisms. Finite element simulations incorporate fiber–matrix interface debonding with cohesive zones and matrix damage with a smeared crack band approach in a unidirectional carbon–carbon composite. Results from a variance-based global sensitivity analysis identifies interfacial and matrix damage parameters as the primary source of variability in fracture behavior. Sobol’ indices indicate that matrix and cohesive zone strengths contribute 94% of the variance in the effective ultimate stress. A local analysis elucidates the relationship between these constituent strength parameters and failure mode by estimating the probability of cohesive, matrix, and mixed-mode dominated failure. Based on the results for 4000 simulations, 93% exhibit mixed-mode or interfacial dominated failure, which underscores the crucial role of fiber–matrix interface debonding in the transverse tensile failure of carbon–carbon composites. These uncertainty quantification results facilitate more efficient model calibration and provide a framework for microstructure-informed failure predictions in the face of manufacturing-induced uncertainty.

36 MATERIALS SCIENCE↗

High burn-up spent nuclear fuel vibration integrity study - 15134

The Oak Ridge National Laboratory (ORNL) has developed the cyclic integrated reversible-bending fatigue tester (CIRFT) approach to successfully demonstrate the controllable fatigue fracture of high burnup (HBU) spent nuclear fuel (SNF) in a normal vibration mode. CIRFT enables examination of the underlying mechanisms of SNF system dynamic performance. Due to the inhomogeneous composite structure of the SNF system, the detailed mechanisms of pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained from a CIRFT system measurement. Therefore, finite element analyses (FEAs) are being used to complement the experimental work by estimating values of local stresses and strains from the measured global moment-curvature. These results and their implications will be used for further investigation. Major findings of CIRFT on the HBU SNF are as follows: - The degree of bonding between pellets, as well as the bonding between pellets and clad in the SNF system plays an important role in the vibration performance of SNF. - Fuel structure contributes to SNF system stiffness. - There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellet and clad interactions. - SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

StingRAY Failure Mode, Effects and Criticality Analysis: WEC Risk Registers

Analysis method to systematically identify all potential failure modes and their effects on the Stingray WEC system. This analysis is incorporated early in the development cycle such that the mitigation of the identified failure modes can be achieved cost effectively and efficiently. The FMECA can begin once there is enough detail to functions and failure modes of a given system, and its interfaces with other systems. The FMECA occurs coincidently with the design process and is an iterative process which allows for design changes to overcome deficiencies in the analysis.Risk Registers for major subsystems completed according to the methodology described in "Failure Mode Effects and Criticality Analysis Risk Reduction Program Plan.pdf" document below, in compliance with the DOE Risk Management Framework developed by NREL.

16 TIDAL AND WAVE POWER↗

Strain isolated ceramic coatings

Plasma sprayed ceramic coatings are used in gas turbine engines to improve component temperature capability and cooling air efficiency. A compliant metal fiber strain isolator between a plasma sprayed ceramic coating and a metal substrate improves ceramic durability while allowing thicker coatings for better insulation. Development of strain isolated coatings has concentrated on design and fabrication of coatings and coating evaluation via thermal shock testing. In thermal shock testing, five types of failure are possible: buckling failure im compression on heat up, bimetal type failure, isothermal expansion mismatch failure, mudflat cracking during cool down, and long term fatigue. A primary failure mode for thermally cycled coatings is designated bimetal type failure. Bimetal failure is tensile failure in the ceramic near the ceramic-metal interface. One of the significant benefits of the strain isolator is an insulating layer protecting the metal substrate from heat deformation and thereby preventing bimetal type failure.

Tolokan, R. P.↗

Meteorological Satellites (METSAT) and Earth Observing System (EOS) Advanced Microwave Sounding Unit-A (AMSU-A) Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL)

This Failure Modes and Effects Analysis (FMEA) is for the Advanced Microwave Sounding Unit-A (AMSU-A) instruments that are being designed and manufactured for the Meteorological Satellites Project (METSAT) and the Earth Observing System (EOS) integrated programs. The FMEA analyzes the design of the METSAT and EOS instruments as they currently exist. This FMEA is intended to identify METSAT and EOS failure modes and their effect on spacecraft-instrument and instrument-component interfaces. The prime objective of this FMEA is to identify potential catastrophic and critical failures so that susceptibility to the failures and their effects can be eliminated from the METSAT/EOS instruments.

Source record↗

Postbuckling behavior of selected flat stiffened graphite-epoxy panels loaded in compression

Results of an experimental study of the postbuckling behavior of selected flat stiffened graphite-epoxy panels loaded in compression are presented. The postbuckling response and failure characteristics of undamaged panels and panels damaged by low-speed impact are described. Each panel had four equally-spaced I-spaced stiffeners and 16- or 24-ply quasi-isotropic skins. Panels with three different stiffener spacings were tested. Some undamaged specimens supported as much as three times their initial buckling load before failing. Failure of all panels initiated in a skin-stiffener interface region. Analytical results obtained from a nonlinear general shell finite element analysis computer code correlate well with typical postbuckling test results up to failure. The analytical modeling detail necessary to predict accurately the response of a panel is described. Test results show that low-speed impact damage can reduce the postbuckling strength of a stiffened panel and that the skin-stiffener interface region is more sensitive to impact damage than the skin midway between stiffeners.

Starnes, J. H., Jr.↗

Mitigating mechanical failure of crystalline silicon electrodes for lithium batteries by morphological design [Morphological design of silicon electrode with anisotropic interface reaction rate for lithium ion batteries]

Although crystalline silicon (c-Si) anodes promise very high energy densities in Li-ion batteries, their practical use is complicated by amorphization, large volume expansion and severe plastic deformation upon lithium insertion. Recent experiments have revealed the existence of a sharp interface between crystalline Si (c-Si) and the amorphous Li x Si alloy during lithiation, which propagates with a velocity that is orientation dependent; the resulting anisotropic swelling generates substantial strain concentrations that initiate cracks even in nanostructured Si. Here we describe a novel strategy to mitigate lithiation-induced fracture by using pristine c-Si structures with engineered anisometric morphologies that are deliberately designed to counteract the anisotropy in the crystalline/amorphous interface velocity. This produces a much more uniform volume expansion, significantly reducing strain concentration. Based on a new, validated methodology that improves previous models of anisotropic swelling of c-Si, we propose optimal morphological designs for c-Si pillars and particles. The advantages of the new morphologies are clearly demonstrated by mesoscale simulations and verified by experiments on engineered c-Si micropillars. The results of this study illustrate that morphological design is effective in improving the fracture resistance of micron-sized Si electrodes, which will facilitate their practical application in next-generation Li-ion batteries. In conclusion, the model and design approach present in this paper also have general implications for the study and mitigation of mechanical failure of electrode materials that undergo large anisotropic volume change upon ion insertion and extraction.

25 ENERGY STORAGE↗

Key Durability Issues with Mullite-Based Environmental Barrier Coatings for Si-Based Ceramics

Plasma-sprayed mullite (3Al2O3.2SiO2) and mullite/yttria-stabilized-zirconia (YSZ) dual layer coatings have been developed to protect silicon -based ceramics from environmental attack. Mullite-based coating systems show excellent durability in air. However, in combustion environments, corrosive species such as molten salt or water vapor penetrate through cracks in the coating and attack the Si-based ceramics along the interface. Thus the modification of the coating system for enhanced crack-resistance is necessary for long-term durability in combustion environments. Other key durability issues include interfacial contamination and coating/substrate bonding. Interfacial contamination leads to enhanced oxidation and interfacial pore formation, while a weak coating/substrate bonding leads to rapid attack of the interface by corrosive species, both of which can cause a premature failure of the coating. Interfacial contamination can be minimized by limiting impurities in coating and substrate materials. The interface may be modified to improve the coating/substrate bond.

Lee, Kang N.↗

An Interface Debonding Model for Integrity Assessment of Nuclear Fuel Rods

The integrity degradation of nuclear fuel rods due to material embrittlement resulting from hydride formation has been extensively investigated. Finite element based fracture mechanics models have been proposed to assess the reduction of load capacity of nuclear fuel rod structures with several distribution scenarios of hydrides. In these finite element models, individual hydrides are modeled by opened cracks distributed in bulk matrix. These models are indeed valid for cases where hydrides fractures occur at low load levels. It is important for finite element models to take into account the cases where hydride fractures occur at high load levels, at which bulk matrix material may undergo reasonable high stress or yield. This requires hydride/bulk matrix interface models that can accommodate both bonded and debonded (fractured or crack initiation) behaviors of hydride/matrix interfaces. However, direct modeling debonding behaviors between hydride and bulk matrix is a great challenge. This is because for ductile structural failure simulations ligaments of bulk matrix often undergo large plastic deformation. Complete solutions often unavailable for crack initiation or debonding in media with finite plastic strain using popular implicit finite element technologies. This paper proposes a new computational framework based on discontinuous Galerkin (DG) finite element formulations for easily handling hydride/matrix interface debonding. We present structural failure simulation results for a quarter plane strain rod model with zircaloy materials. It is concluded that the proposed DG interface debonding model is powerful in simulating structural failure due to hydride failure in bulk media with finite plastic deformation. (author)

36 MATERIALS SCIENCE↗

Postbuckling behavior of selected curved stiffened graphite-epoxy panels loaded in axial compression

Results of an experimental and analytical study of the postbuckling behavior of selected curved stiffened graphite-epoxy panels loaded in axial compression are presented. The postbuckling response and failure characteristics of the panels are described. Each panel had four equally-spaced I-shaped stiffeners and 16-ply quasi-isotropic skins. Panels with three different stiffener spacings were tested. Failure of all panels initiated in a skin-stiffener interface region. Analytical results from a nonlinear general shell finite element analysis computer code correlate well with typical postbuckling test results up to failure. The analytical modeling detail necessary to predict accurately the response of the panel is described. Measured initial geometric imperfections were included in the postbuckling analysis.

Knight, N. F., Jr.↗

High Temperature Oxidation Behavior of Ni-based High Entropy Superalloys

A new class of polycrystalline gamma-prime strengthened superalloys with alloy compositions of (wt%) Ni-20Co-13Cr-6Fe-4Al-3W-2Mo-(4-x)Nb-(x)Ti (x = 0,1,2) were subjected to cyclic oxidation exposures in dry air at 800 °C for 3600 h. The alloys were borderline chromia/alumina formers, showing good oxidation resistance relative to commercially available materials of similar composition. While all alloys formed alumina scales initially, only the alloy with the lowest Ti/Nb ratio retained an alumina scale for the duration of the exposure. Formation of a continuous layer of rutile TiO 2 at the alumina/alloy interface is proposed to cause eventual alumina failure for the alloys containing Ti.

36 MATERIALS SCIENCE↗

Compression molding of anisotropic NdFeB bonded magnets in a polycarbonate matrix

Anisotropic bonded Nd 2 Fe 14 B (NdFeB) magnets in a polycarbonate (PC) binder matrix are fabricated using a compression molding process. The weight fractions (w.f.) of NdFeB in PC on the batch mixer are 20, 50, 75, 85 and 95% compared to the twin screw extruder with 20, 50 and 75% respectively. The density of the 95% batch mixed magnets fabricated was 5.34 g/cm 3 and the magnetic properties are, intrinsic coercivity H ci = 942.99 kA/m, remanence B r = 0.86 T, and energy product (BH) max = 120.96 kJ/m 3 . Furthermore, the measured tensile properties are in the range of 27-59 MPa, comparable to that of polyamide (PA), polyphenylene sulfide (PPS) bonded magnets and demonstrating potential for bonded magnet applications. Scanning electron microscopy showed that the onset of failure occurs in the magnetic particle- matrix interface. This study demonstrates that compression additive molding technique can be used to fabricate high performance NdFeB polycarbonate composite magnets with improved mechanical properties.

36 MATERIALS SCIENCE↗