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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Additive friction stir deposition induced stress ripples in aluminum alloy

In additive manufacturing, modification of the viscosity of softened or molten metal plays a significant role in the development of mechanical properties distribution. Similar to soft polymers, molten or softened metal usually exhibits vastly different viscoelastic properties. During scratching tests, viscoelastic polymers undergo spatiotemporal stress development and relaxation, causing stress ripples to form on their surfaces. Here, it is observed that friction stir-based solid-state manufacturing can yield similar stress ripples on softened aluminum alloys due to the linear motion of the deposition tool. Softened aluminum alloys exhibit viscoelastic and viscoplastic responses similar to polymeric material during the solid-state deposition process. In the final product, residual stress ripples appear on the surface of the metal alloy due to periodic residual stress relaxation, leading to oscillatory behavior from the bulk mechanical properties of the material. The orientation of the in-built stress pattern formed in the bulk of the additively manufactured metal alloy underneath the visually evident onion ring-like surface pattern formation is diametrically in the opposite direction. The experimentally observed results are consistent with analytical calculation and numerical simulations in terms of behaviors.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Effect of stress and temperature on zero group velocity Lamb modes

Zero group velocity (ZGV) Lamb wave resonances are highly localized and sensitive to changes in material properties, making them a viable option for probing residual stresses and elastic nonlinearity through acoustoelastic effects. Temperature changes also influence ZGV modes and need to be accounted for, particularly when measuring the small frequency shifts associated with acoustoelastic effects. We use a laser-based ultrasonic system to measure the third-order elastic constants of several materials. A temperature compensation scheme is devised to remove the effects of temperature fluctuations from the measurements. Furthermore, the measured third-order elastic constants are used to predict the temperature dependence of the ZGV resonances using thermo-acoustoelasticity theory, and these predictions are compared to experimental measurements. We find that thermo-acoustoelasticity theory was unable to reliably predict the shift in ZGV resonances with temperature. These results could have important implications in understanding the limitations of thermo-acoustoelasticity theory and in developing precision ZGV resonance-based systems to detect and quantify residual stress in parts, a particularly relevant problem in additive manufacturing techniques including powder bed fusion and directed energy deposition.

Engineering↗
DOE OSTI2026

An Integrated Computational Materials Engineering (ICME) Approach to Design Nonlinear Transition Zones Between Dissimilar Metals

Current approaches to designing graded transition joints (GTJs) between dissimilar metals often rely on linear changes in both composition profiles and thickness of each sublayer. This increases fabrication cost and may not be optimal with respect to residual stress or the formation of undesirable phases. Here, in this study, GTJs between P91 ferritic/martensitic steel and 347H austenitic stainless steel were designed using Integrated Computational Materials Engineering (ICME) principles with nonlinear composition and length profiles. Guided by inputs from classical mechanics and CALPHAD predictions of carbon chemical potential, a novel transition zone consisting of five discrete compositions was proposed, with the thickness of each sublayer varying according to a brachistochrone-inspired distribution. In addition to carbon potential gradients, CALPHAD was used to predict coefficients of thermal expansion, which were incorporated into finite element models to evaluate stress evolution. The proposed nonlinear design resulted in a smoother carbon potential gradient, lower carbon depletion at the P91 interface, and a comparable residual stress under long-term thermal exposure, compared to a conventional linear design using ten sublayers with equal thickness. This work introduces a brachistochrone-inspired distribution for GTJ design, offering a general framework for optimizing graded interfaces between dissimilar metals.

Directed Energy Deposition↗
NASA NTRS2010

Experimental Evaluation of Fatigue Crack Initiation from Corroded Hemispherical Notches in Aerospace Structural Materials

A test program was developed and executed to evaluate the influence of corroded hemispherical notches on the fatigue crack initiation and propagation in aluminum 7075-T7351, 4340 steel, and D6AC steel. Surface enhancements such as shot peening and laser shock peening were also incorporated as part of the test effort with the intent of improving fatigue performance. In addition to the testing, fracture mechanics and endurance limit based analysis methods were evaluated to characterize the results with the objective of challenging typical assumptions used in modeling fatigue cracks from corrosion pits. The results specifically demonstrate that the aluminum and steel alloys behave differently with respect to fatigue crack initiation from hemispherical corrosion pits. The aluminum test results were bounded by the fracture mechanics and endurance limit models while exhibiting a general insensitivity to the residual stress field generated by shot peening. The steel specimens were better characterized by the endurance limit fatigue properties and did exhibit sensitivities to residual stresses from the shot peening and laser shock peening

Garcia, Daniel B.↗
NASA NTRS1992

Improvement in surface fatigue life of hardened gears by high-intensity shot peening

Two groups of carburized, hardened, and ground spur gears that were manufactured from the same heat vacuum induction melted vacuum arc melted (VIM VAR) AISI 9310 steel were endurance tested for surface fatigue. Both groups were manufactured with a standard ground 16 rms surface finish. One group was subjected to a shot peening (SP) intensity of 7 to 9A, and the second group was subjected to a SP intensity of 15 to 17A. All gears were honed after SP to a surface finish of 16 rms. The gear pitch diameter was 8.89 cm. Test conditions were a maximum Hertz stress of 1.71 GPa, a gear temperature of 350 K, and a speed of 10000 rpm. The lubricant used for the tests was a synthetic paraffinic oil with an additive package. The following results were obtained: The 10 pct. surface fatigue (pitting) life of the high intensity (15 to 17A) SPed gears was 2.15 times that of the medium intensity (7 to 9A) SPed gears, the same as that calculated from measured residual stress at a depth of 127 microns. The measured residual stress for the high intensity SPed gears was 57 pct. higher than that for the medium intensity SPed gears at a depth of 127 microns and 540 pct. higher at a depth of 51 microns.

Townsend, Dennis P.↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
NASA NTRS1990

Mechanical behaviors of ceramic matrix composites with matrix cracking and fiber debonding

The purpose of this paper is to summarize the current research of the authors on the mechanical behaviors of ceramic matrix composites, including (1) the stress distributions in a composite with matrix cracking and interfacial debonding, (2) the critical strain for matrix cracking, and (3) the effects of fiber/matrix debonding and thermal residual stresses on the critical strain. The stress fields in both bonded and debonded regions are evaluated by taking into account thermal effects. An energy balance approach is followed to determine the critical strain for matrix cracking. From the general equation of the critical strain for matrix cracking, close form solutions have been obtained for two limiting cases: perfect bonding and complete debonding. Numerical solutions are given for the cases of partial fiber debonding and nonzero debonding energy. It is found that thermal residual stresses and the debonding energy have significant effects on the critical strain.

Kuo, Wen-Shyong↗
NASA NTRS2014

Fabrication of Turbine Disk Materials by Additive Manufacturing

Precipitation-strengthened, nickel-based superalloys are widely used in the aerospace and energy industries due to their excellent environmental resistance and outstanding mechanical properties under extreme conditions. Powder-bed additive manufacturing (AM) technologies offer the potential to revolutionize the processing of superalloy turbine components by eliminating the need for extensive inventory or expensive legacy tooling. Like selective laser melting (SLM), electron beam melting (EBM) constructs three-dimensional dense components layer-by-layer by melting and solidification of atomized, pre-alloyed powder feedstock within 50-200 micron layers. While SLM has been more widely used for AM of nickel alloys like 718, EBM offers several distinct advantages, such as less retained residual stress, lower risk of contamination, and faster build rates with multiple-electron-beam configurations. These advantages are particularly attractive for turbine disks, for which excessive residual stress and contamination can shorten disk life during high-temperature operation. In this presentation, we will discuss the feasibility of fabricating disk superalloy components using EBM AM. Originally developed using powder metallurgy forging processing, disk superalloys contain a higher refractory content and precipitate volume fraction than alloy 718, thus making them more prone to thermal cracking during AM. This and other challenges to produce homogeneous builds with desired properties will be presented. In particular, the quality of lab-scale samples fabricated via a design of experiments, in which the beam current, build temperature, and beam velocity were varied, will be summarized. The relationship between processing parameters, microstructure, grain orientation, and mechanical response will be discussed.

oxidation↗
NASA NTRS1983

Stress studies in EFG

Stress distributions were calculated for a creep law to predict a rate of plastic deformation. The expected reduction in stresses is obtained. Improved schemes for calculating growth system temperature distributions were evaluated. Temperature field modeling examined the possibility of using horizontal temperature gradients to influence stress distribution in ribbon. The defect structure of 10 cm wide ribbon grown in the cartridge system was examined. A new feature is identified from an examination of cross sectional micrographs. It consists of high density dislocation bands extending through the ribbon thickness. A four point bending apparatus was constructed for high temperature study of the creep response of silicon, to be used to generate defects for comparison with as grown defects in ribbon. The feasibility of laser interferometric techniques for sheet residual stress distribution measurement is examined. The mathematical formalism for calculating residual stress from changes in surface topology caused by an applied stress in a rectangular specimen was developed, and the system for laser interferometric measurement to obtain surface topology data was tested on CZ silicon.

Source record↗
DOE OSTI2026

Spatially resolved phase transformation mapping in 410 stainless steel during additive manufacturing visualized via real-time infrared data

Here, in this study, we demonstrate that spatially resolved cooling curves derived from real-time infrared (IR) thermography during additive manufacturing (AM) can capture spatial variations in phase transformation temperatures through cooling curve analysis (CCA). Using this approach, we show that during laser hot-wire deposition of 410 stainless steel (410SS), the martensite start temperature (M s ) evolves dynamically throughout the build. The M s temperature is spatially nonuniform, ranging from 185 °C to 348 °C, with the lowest values toward the build center and higher values toward the upper region of the deposit. In the lower portion of the build, no M s inflection is detected via CCA, consistent with transformation occurring earlier during thermal cycling followed by tempering during subsequent thermal cycles. These trends in M s are corroborated by characterizing the microstructure by electron backscatter diffraction (EBSD). Traditionally, M s is assumed to be constant, and a single interpass temperature is applied during both deposition and residual stress modeling. Our results demonstrate that IR-derived cooling curves provide a route to spatially and temporally resolved transformation temperature tracking for dynamic interpass control and improved residual-stress modeling.

Additive manufacturing↗
DOE OSTI2026

Flaw Tolerance Assessment for DOE Standard SNF Dry Storage Canisters - 26550

The U.S. DOE has designed four spent nuclear fuel (SNF) dry storage canisters for storing DOE standardized SNFs. The DOE standard canisters are cylindrical shells with a diameter of 24 inches (610 m) or 18 inches (457 m), a wall thickness of 0.5 inches (12.7 m) or 0.375 inches (9.53 m), and a length of 15 feet (4.57 m) or 10 feet (3.05 m). These DOE canister geometries are completely different from commercial canisters. The latter may experience chloride-induced stress cracking corrosion (CI-SCC) because they are stored near coastal regions. The former may not experience CI-SCC but face different challenges because they are stored in the SNF storage facilities. Because of large residual stresses, mechanical flaws may occur in the DOE canisters during long-distance transportation or lifting handling. To date, only limited structural integrity analyses were carried out through drop tests on the DOE canisters, but a more general flaw tolerance assessment has not been performed. Therefore, the failure assessment diagram (FAD)-based fracture mechanics method, as codified by the latest API 579-1/ASME FFS-1-2021 Edition, is adopted in this work to assess surface flaw tolerance for DOE canisters under operation loading and welding residual stresses (WRS), where the new code-recommended WRS distributions are used. To more adequately consider the transverse distribution of WRS, an equivalent WRS distribution is proposed to account for the WRS reduction with distance from the weld centerline. Moreover, the closed-form solutions of stress intensity factor K, which serves as the crack driving force during subcritical crack growth, are developed from the tabular data of the K factors provided in API 579-1/ASME FFS-1 and used to determine more accurate flaw sizes at flaw instability. Subsequently, the Level 2 assessment procedures with 12 assessment steps, as codified and detailed in API 579-1 and ASME FFS-1, are followed to assess the flaw tolerance for the surface flaws in the DOE standard canisters with consideration of normal or accident operation loads combined with WRS. The assessment results show that the four designs of DOE standard canisters can tolerate all surface flaws that meet the code permitted maximum sizes of a flaw length of 8 inches (i.e., 200 mm) and a flaw depth of 80% wall thickness. This demonstrates that all designs of DOE standard canisters are robust and reliable.

DOE standard canister↗
NASA NTRS1985

Silicon sheet surface studies

Results of the program are presented on developing an understanding of the basic mechanisms of abrasion and wear of silicon and on the nondestructive measurement of residual stresses in sheet silicon. Experiments were conducted at various temperatures and in the presence of various fluids. In abrasive wear, it was shown that dislocations, microtwins, and cracks are generated beneath the contact surface. Residual stresses in ribbon by the edge defined film growth process were measured by use of a shadow moire interferometry technique.

Danyluk, S.↗
NASA NTRS1990

Interfacial sliding near a free surface in a fibrous or layered composite during thermal cycling

This paper presents a simple shear lag model of interfacial sliding at a free surface in a layered or continuous fiber composite. The interface is characterized by a critical interfacial shear stress, tau0, which might represent the critical stress for frictional sliding at a weakly bonded interface, or the shear flow stress of a thin ductile interface layer at a well bonded interface. The history, during heating and cooling, of the relative normal displacement of the reinforcing inclusions and the matrix on a free surface cut normal to the inclusions is calculated and shown to depend on both the absolute value and the temperature dependence of tau0, as well as on the magnitudes of the bulk residual stresses. The variety of possible displacement histories suggests that they are a rich source of information about tau0 and the residual stresses.

Cox, B. N.↗
NASA NTRS1975

Measurement of residual strains in boron-epoxy and glass-epoxy laminates

Embedded-strain-gage techniques were developed and used for measuring strains in composite angle-ply laminates during curing and thermal cycling. The specimens were 2.54 by 22.9 cm eight-ply boron-epoxy and S-glass-epoxy laminates. Unidirectional specimens were used for control purposes. Strain readings were corrected for the purely thermal output of the gages obtained from an instrument quartz reference specimen. The strains measured during the cooling part of the curing cycle were in agreement with those recorded during subsequent thermal cycling, indicating that residual stresses induced during curing are primarily caused by differential thermal expansions of the various plies. Restraint strains were computed for the 0-deg and 45-deg plies of the angle-ply laminates tested, and the residual stresses obtained using the anisotropic constitutive relations and taking into account the temperature dependence of stiffnesses and strains.

Daniel, I. M.↗
NASA NTRS1984

Structural Characterization of Solar Silicon

Compared to single crystal silicon, solar silicon generally contains large residual stresses and numerous structural defects. During subsequent processing, the defect structure can undergo further changes since, at the high temperatures required for diffusion, dislocations are sufficiently mobile to rearrange themselves in patterns which reduce long range residual stresses. This process, which is similar to the polygonization of strained metals, has no counterpart in single crystal silicon. Many of the solar silicon materials are grown from graphite dies and crucibles and therefore contain carbon concentrations in excess of 1E18. The interactions between carbon, crystal defects, intrinsic point defects, oxygen and diffusing dopants are discussed.

Ast, D. G.↗
NASA NTRS1984

Deposition stress effects on thermal barrier coating burner rig life

A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

Watson, J. W.↗
NASA NTRS1993

An analytical/numerical correlation study of the multiple concentric cylinder model for the thermoplastic response of metal matrix composites

The utility of a recently developed analytical micromechanics model for the response of metal matrix composites under thermal loading is illustrated by comparison with the results generated using the finite-element approach. The model is based on the concentric cylinder assemblage consisting of an arbitrary number of elastic or elastoplastic sublayers with isotropic or orthotropic, temperature-dependent properties. The elastoplastic boundary-value problem of an arbitrarily layered concentric cylinder is solved using the local/global stiffness matrix formulation (originally developed for elastic layered media) and Mendelson's iterative technique of successive elastic solutions. These features of the model facilitate efficient investigation of the effects of various microstructural details, such as functionally graded architectures of interfacial layers, on the evolution of residual stresses during cool down. The available closed-form expressions for the field variables can readily be incorporated into an optimization algorithm in order to efficiently identify optimal configurations of graded interfaces for given applications. Comparison of residual stress distributions after cool down generated using finite-element analysis and the present micromechanics model for four composite systems with substantially different temperature-dependent elastic, plastic, and thermal properties illustrates the efficacy of the developed analytical scheme.

Pindera, Marek-Jerzy↗
NASA NTRS2021

Micromechanics-based Modeling of Laminated SiC/SiC Ceramic Matrix Composites

The behavior and response of ceramic matrix composites (CMCs), in particular silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC), is affected by many factors such as variation of fiber volume fraction, residual stresses resulting from processing of the composites at high temperature, random microstructures, and the presence of matrix flaws (e.g., voids, pores, cracks etc.) as well as general material nonlinearity and heterogeneity that occurs randomly in a composite. Residual stresses arising from the phase change of constituents are evaluated in this paper and it is shown that they do influence composite strength and need to be properly accounted for. Additionally, the microstructures (location of fiber centers, coating thickness etc.) of advanced CMCs are usually disordered (or random) and fiber diameter and strength typically have a distribution. They rarely resemble the ordered fiber packing (square, rectangular, or hexagonal) that is generally assumed in micromechanics-based models with periodic boundary conditions for computational expediency. These issues raise the question of how should one model such systems effectively? Can an ordered hexagonal packed repeating unit cell (RUC) accurately represent the random microstructure behavior? How many fibers need to be included to enable accurate representation? Clearly, the number of fibers within an RUC must be limited to insure a balance between accuracy and efficiency. NASA’s in-house micromechanics-based code MAC/GMC provides a framework to analyze such RUCs for the overall composite behavior and the FEAMAC computer code provides linkage of MAC/GMC to the commercial FEA code, ABAQUS. The appropriate level of discretization of the RUC as well as the analysis method employed, i.e., Generalized Method of Cells (GMC) or High Fidelity Generalized Method of Cells (HFGMC), is investigated in this paper in the context of a unidirectional as well as a cross-ply laminated CMC. Results including effective composite properties, proportional limit stress (an important design parameter) and fatigue are shown utilizing both GMC as well as HFGMC. Finally, a few multiscale analyses are performed on smooth bar test coupons as well as test coupons with features such as open-hole and double notches using FEAMAC. Best practices and guidance are provided to take these phenomena into account and keep a proper balance between fidelity (accuracy) and efficiency. Following these guidelines can account for important physics of the problem and provide significant advantages when performing large multiscale composite structural analyses.

Ceramic Matrix Composites↗