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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Instrumentation and Control Selection for the 12 GeV Hall-B Magnets at Jefferson Lab

Here, as part of the Jefferson Lab 12 GeV accelerator upgrade, the Experimental Physics Hall B detector system requires two superconducting magnets – a Torus and a Solenoid. The specifications required maximum space for the detectors which led to the choice of conduction cooling for each magnet. The Torus consists of 6 trapezoidal 'race-track'-type coils connected in series with an operating current of 3770 A. The Solenoid is an actively shielded 5 Tesla magnet consisting of 5 coils connected in series operating at 2416 A. Within the hall the two magnets are located in close proximity to each other and are surrounded by particle detectors. We describe the philosophy behind the instrumentation selection and control design that accounts for this proximity and other challenging working conditions. We describe the choice of sensor technologies, as well as the control and data acquisition methods. The magnet power and cryogenic control sub-systems are implemented using Allen Bradley Control Logix 1756-L72 Programmable Logic Controllers. Sensor instrumentation read-backs are routed into the PLC via National Instruments cRIO hardware (Field Programmable Gate Arrays or FPGA/RT application) using Jefferson Lab designed FPGA-based multi-sensor-excitation-chassis. Configuration, monitoring, and alarm handlers for the magnet systems are provided via an Experimental Physics Instrumentation & Control System interface (EPICS). Failure Modes and Effects Analysis (FMEA) and the requirement to monitor critical parameters during operation guided the selection of instrumentation and associated hardware. The design of the quench protection and voltage tap sub-systems was driven by the anticipated level of voltages developed during a magnet quench. The primary hard-wired quench detection and protection sub-system together with the secondary PLC-based protection sub-system is also discussed. The successful commissioning and subsequent performance of these magnets demonstrates the robustness of the design and implementation approach that was adopted by the Jefferson Lab team and serves as an excellent 'How To' guide for future projects of this size and complexity.

12 GeV↗
DOE OSTI2021

Deformation and fracture characteristics of zirconium plate produced via ultrasonic additive manufacturing

Abstract The microstructural evolution, deformation modes, and fracture mechanisms of zirconium plate produced using ultrasonic additive manufacturing (UAM) are presented. In addition to conventional tensile testing techniques, digital image correlation captured highly variable strain accumulation in specimens loaded perpendicular or parallel to the build height (Z). When tested in parallel to Z, delamination at prior foil/foil interfaces creates strain localization noticeable in strain rate maps, whereas specimens loaded perpendicular to Z illustrate conventional strain hardening until necking accelerates delamination. Although bond strengths are statistically and spatially variable, in situ electron backscattering diffraction tests illustrate the ability for grains near interfaces to accommodate strain with twinning and slip modes consistent with conventionally produced zirconium alloys. Finally, mixtures of ductile and delamination-induced fracture highlight the interface-driven failure modes of UAM zirconium plate in the as-built condition. Graphic abstract

36 MATERIALS SCIENCE↗
DOE OSTI2025

Optimization of Functionally Graded Materials Using Additive Manufacturing: An Integrated Experimental and Computational Approach (Abbreviated Final Report)

Many advanced technologies, such as next-generation energy systems, aerospace vehicles, and defense platforms, require materials that can withstand extreme environments, including high temperatures, corrosion, and radiation, while remaining strong and lightweight. Traditionally, joining different materials to achieve these properties introduces weak, failure-prone interfaces and defects that limit performance. Our research aimed to overcome this challenge by using additive manufacturing, specifically directed energy deposition, to create functionally graded materials—components with smooth transitions between different metals. This approach eliminates sharp boundaries and allows for tailored material properties throughout a part.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Study on Fracture of Fiber-Reinforced Polymeric Composites Using Spiral Notch Torsion Test

Fiber-reinforced polymer-matrix composites have been widely applied in various areas due to their excellent mechanical properties. In this study, carbon fiber-reinforced polymer-matrix composites and glass fiber-reinforced polymer-matrix composites failure tests under quasi static torsion have been demonstrated by using spiral notch torsion test methodology. Three types of cylindrical specimens with different fiber orientations were prepared and tested. For both composites, after increase stage, A type exhibited limited stress variations before the sudden failure, whereas B type showed gradual failure with torque drops. Displacement contours, stress contours and energy release rates were acquired using the anisotropic elastic finite element models. Microscopic characterization exhibited that the failure of A type occurred along interfaces between fibers and matrices, whereas circular cracks in B type propagated alternatively between polymeric matrices and interfaces. Type C failure is similar to type A whereas with a curvature observed on the fracture surface.

Du, Fen↗
DOE OSTI2025

Micro-tensile testing of neutron-irradiated Al/Zr and Zr/U-Mo diffusion bonds

This study focuses on micro-tensile testing of neutron-irradiated Al/Zr and Zr/U-Mo diffusion bonds, which are integral to the structure and performance of nuclear fuel plates used in the fuel being developed for U.S. high-power research reactors. During fabrication, two distinct diffusion bonds occur—one at the Zr/U-10Mo interface via roll bonding, and the Zr/Al interface via hot isostatic pressing at 833 K. This work utilizes micro-tensile testing specimens approximately 7 × 7 × 18 μm 3 , which are sufficiently large to encompass the identified diffusion zones to evaluate the failure strength and identify the failure location. For the Zr/Al interface, all failures occurred in the bulk aluminum. The average yield strength, ultimate strength, and strain at failure for the two parent samples were: 125 ± 10 MPa, 139 ± 24 MPa, 156 ± 21 MPa, 185 ± 14 MPa, 37.9 ± 5.6 %, and 29.7 ± 3.4 %, respectively. For specimens across the Zr/U-Mo interface, failures occurred either in the bulk Zr or U-Mo, with no failures observed in the diffusion region. For specimens that failed in the bulk Zr the failure strength and strain for the two parent samples were 570 MPa, 710 ± 131 MPa, and 43.3 %, 27.3 ± 6.6 % respectively. The specimens that failed in the bulk U-Mo had failure strengths and strains of 596 ± 32 MPa, 548 ± 124 MPa, and 2.2 ± 1.3 %, 1.5 ± 0.6 % respectively. In conclusion, these findings support the development of accurate thermo-mechanical models for irradiated fuel performance by identifying the mechanical limits and failure locations within the bonded regions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Influence of nanoscale interfaces on the dynamic deformation and spall failure of Cu–Fe alloy microstructures

Additively manufactured immiscible Cu–Fe alloys can exhibit a distribution of nanoscale interfaces due to the distribution of nanoscale clusters in the equilibrium and metastable phases. Molecular dynamics simulations investigate the role of such interfaces on the phase stability and transformation behavior during shock compression, as well as the mechanisms of damage nucleation during spall failure. The model multiphase Cu–Fe systems studied here comprise a distribution of Fe clusters in an FCC Cu matrix, as well as Cu clusters in a BCC Fe matrix. The length scales of the nanoscale clusters determine the energetics of the interfaces that can result in FCC/BCC (equilibrium) or FCC/FCC (metastable) interfaces in the Cu system matrix, and BCC/FCC (equilibrium) or BCC/BCC (metastable) interfaces in the Fe matrix. The MD simulations demonstrate that nanoscale metastable interface microstructures can induce plastic deformation and also stabilize phases or suppress phase transformations in metastable phase clusters. In contrast, equilibrium interfaces can influence phase transformation thresholds and serve as additional void nucleation sites during failure.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Detecting divertor damage during steady state operation of Wendelstein 7-X from thermographic measurements

Wendelstein 7-X (W7-X) aims to demonstrate the reactor capability of the stellarator concept, by creating plasmas with pulse lengths of up to 30 min at a heating power of up to 10 MW. The divertor plasma facing components will see convective steady state heat flux densities of up to 10 MW/m 2 . These high heat flux target elements are actively cooled and are covered with carbon fibre reinforced carbon (CFC) as plasma facing material. The CFC is bonded to the CuCrZr cooling structure. Over the life time of the experiment this interface may weaken and cracks can occur, greatly reducing the heat conduction between the CFC tile and the cooling structure. Furthermore, there is not only the need to monitor the divertor to prevent damage by overheating but also the need to detect these fatigue failures of the interface. A method is presented for an early detection of fatigue failures of the interface layer, solely by using the information delivered by the IR-cameras monitoring the divertor. This was developed and validated through experiments made with high heat flux target elements prior to installation in W7-X.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

A robust interface finite element formulation for modeling brittle material failure problems

Abstract Failure of many brittle materials and structures can be modeled using interface‐oriented finite elements combined with intrinsic cohesive zone models. The discontinuous Galerkin (DG) finite element method provides an innovative framework for modeling brittle crack propagation with zero‐thickness interface elements, which can accommodate extrinsic cohesive laws to avoid the artificial compliance required in intrinsic cohesive models. However, robust formulations and implementations of DG methods are critical in alleviating the well‐known convergence issues for both crack nucleation and propagation with reduced instability. This paper presents a robust interface element formulation by modifying the incomplete interior penalty Galerkin (IIPG) method, which successfully avoids the initial element interface penetration across elements that occurs prior to crack nucleation, and thereby greatly reduces the instability issue as cracks open. We further verified and validated our implementation by using a bar tension test and a beam fracturing benchmark. The robustness of our proposed interface element method was demonstrated by a micromechanics fiber/matrix debonding problem with 64 fibers embedded in a bulk matrix.

Liu, Ruijie↗
DOE OSTI2025

3D interface size effects on slip transfer in Ti/Nb nanolaminates

Two-phase nanolaminates are well-renowned for achieving extraordinarily high strengths but at the sacrifice of reduced toughness and strain to failure. Recently ”thick” interfaces, or so called 3D interfaces, in Cu/Nb nanolaminates were experimentally shown to improve both of these mechanical properties. Here, in this work, we study the effect of 3D interfaces in the hexagonal close packed (HCP)/body centered cubic (BCC) Ti/Nb nanolaminate system. Nanoindentation hardness testing suggests increased strength with the introduction of a 3D Ti–Nb interface and a positive size effect with increases in 3D interface thickness from 5 nm to 20 nm. To understand this effect from a single dislocation perspective, we present a phase-field dislocation dynamics (PFDD) model for multi-phase HCP/BCC systems. We employ the model to simulate stress-driven transfer of single dislocations across 3D Ti/Nb interfaces of various thicknesses. Our results show that the critical stress for slip transfer increases with the thickness of the interface. This positive size effect is stronger for transfer from basal or prismatic dislocations in the Ti layer to 110$\langle$111$\rangle$ dislocations in the Nb layer than the reverse. For this Ti/Nb system, a critical thickness of 2 nm is identified at which the asymmetry in slip transfer is minimized. This work showcases 3D interfaces as a beneficial microstructure modification to strengthen as well as reduce anisotropy in nanocrystalline materials containing HCP phases.

Dislocations↗
DOE OSTI2024

TiO 2 /TiN Interface Enables Integration of Ni 5 P 4 Electrocatalyst with a III–V Tandem Photoabsorber for Stable Unassisted Solar-Driven Water Splitting

H 2 production by direct photoelectrochemical (PEC) water splitting has remained unachievable commercially, mainly due to rapid failure at the interface between the photoabsorber(s) and catalyst(s). PEC devices made from multijunction III-V semiconductors with platinum group metal (PGM) catalysts have yielded impressive initial solar-to-H 2 (STH) efficiency >19%, which rapidly corrodes in aqueous electrolytes. Here, TiO 2 /TiN layers were fused to create a bifunctional interface between a GaInP 2 /GaAs III-V tandem photoabsorber and a polycrystalline Ni 5 P 4 HER catalyst. Here, the TiO 2 serves as a conducting corrosion barrier, while a thin layer of much denser TiN (1 nm) blocks interlayer diffusion during fabrication. This strategy allows the elevated temperatures needed to crystallize the Ni 5 P 4 nanoparticles and fuse to the TiO 2 /TiN junction to achieve minimal optical loss without damaging the sensitive photoasbsorber. The resulting photocathode exhibits an initial STH efficiency of 11.4%-13.2% in sodium phosphate electrolyte at neutral pH 7. It operated continuously for over 200 h without failure above 10% STH efficiency, exceeding all previous benchmarks. The earth-abundant Ni 5 P 4 catalyst replaces costly PGM catalysts at comparable HER activity in neutral, acidic, or basic pH electrolytes.

08 HYDROGEN↗
DOE OSTI2017

Interface-correlated bonding properties for a roll-bonded Ti/Al 2-ply sheet

Highlights: • The feasible post roll-bonding annealing condition of Ti/Al clad was deduced. • The optimum thickness of the TiAl{sub 3} IMC diffusive layer is about 200 nm. • A ‘zipper-like’ failure mode at the interface yields the maximum bonding strength. - Abstract: We investigated the influence of annealing conditions on the interface-correlated microstructural evolution and subsequent bonding properties of a warm roll-bonded Ti/Al clad sheet. A TiAl{sub 3} intermetallic compound layer with a thickness of 160 nm was initially generated at the joint interface between the Ti and Al alloys by warm rolling. When the annealing time and temperature were increased to a maximum of 6 h and 650 °C, respectively, the thickness of the TiAl{sub 3} layer increased to 320 nm. The feasible annealing conditions for the optimum bonding strength were within 550 °C-6 h and 600 °C-3 h. An improvement in the bonding strength between Ti and Al is strongly correlated with the generation of considerable metallurgical bonding. This is manifested in the zipper-like failure mode that occurs at the TiAl{sub 3} joint interface for a layer thickness of less than 300 nm.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

In recent years, there has been considerable effort to modernize existing and new nuclear power plants with digital instrumentation and control systems (DI&C). However, there has also been considerable concern both by industry and regulatory bodies for the risk and consequence analysis of these systems. Of particular concern are digital common cause failures (CCFs) specifically related to software defects. These “misbehaviors” by the software can occur in both the control and monitoring of a system. While many new methods have been proposed to identify potential software failure modes, such as Systems-theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), etc., these methods are focused primarily on the control action pathway of a system. In contrast, the information feedback pathway lacks unsafe control actions (UCAs), which are typically related to software basic events; thus, assessment of software basic events in such systems is unclear. In this work, we present the idea of intermediate processors and unsafe information flow (UIF) to help safety analysts trace failure mechanisms in the feedback pathway and how they can be integrated into a fault tree for improved assessment capability. The concepts presented are demonstrated in two comprehensive case studies, a smart sensor integrated platform for unmanned autonomous vehicles and another on a representative advanced human system interface (HSI) for safety critical plant monitoring. The qualitative software basic events are identified, and a fault tree analysis is conducted based on a modified Redundancy-guided Systems-theoretic Hazard Analysis (RESHA) methodology. The case studies demonstrate the use of UIF and intermediate processors in the fault tree to improve traceability of software failures in highly complex digital instrumentation feedback. The improved method can also clarify fault tree construction when multiple component dependencies are present in the system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

In recent years, there has been considerable effort to modernize existing and new nuclear power plants with digital instrumentation and control systems (DI&C). However, there has also been considerable concern both by industry and regulatory bodies for the risk and consequence analysis of these systems. Of particular concern are digital common cause failures (CCFs) specifically related to software defects. These “misbehaviors” by the software can occur in both the control and monitoring of a system. While many new methods have been proposed to identify potential software failure modes, such as Systems-theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), etc., these methods are focused primarily on the control action pathway of a system. In contrast, the information feedback pathway lacks unsafe control actions (UCAs), which are typically related to software basic events; thus, assessment of software basic events in such systems is unclear. In this work, we present the idea of intermediate processors and unsafe information flow (UIF) to help safety analysts trace failure mechanisms in the feedback pathway and how they can be integrated into a fault tree for improved assessment capability. The concepts presented are demonstrated in two comprehensive case studies, a smart sensor integrated platform for unmanned autonomous vehicles and another on a representative advanced human system interface (HSI) for safety critical plant monitoring. The qualitative software basic events are identified, and a fault tree analysis is conducted based on a modified Redundancy-guided Systems-theoretic Hazard Analysis (RESHA) methodology. The case studies demonstrate the use of UIF and intermediate processors in the fault tree to improve traceability of software failures in highly complex digital instrumentation feedback. The improved method can also clarify fault tree construction when multiple component dependencies are present in the system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Evaluating and extending user-level fault tolerance in MPI applications

The user-level failure mitigation (ULFM) interface has been proposed to provide fault-tolerant semantics in the Message Passing Interface (MPI). Previous work presented performance evaluations of ULFM; yet questions related to its programability and applicability, especially to non-trivial, bulk synchronous applications, remain unanswered. In this article, we present our experiences on using ULFM in a case study with a large, highly scalable, bulk synchronous molecular dynamics application to shed light on the advantages and difficulties of this interface to program fault-tolerant MPI applications. We found that, although ULFM is suitable for master–worker applications, it provides few benefits for more common bulk synchronous MPI applications. Furthermore, to address these limitations, we introduce a new, simpler fault-tolerant interface for complex, bulk synchronous MPI programs with better applicability and support than ULFM for application-level recovery mechanisms, such as global rollback.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Shock-induced twinning/detwinning and spall failure in Cu–Ta nanolaminates at atomic scales

Here, this study provides new insights into the role of interfaces on the deformation and failure mechanisms in shock-loaded Cu–Ta–Cu trilayer system. The thickness of the Ta layer, piston velocities, and shock pulse durations were varied to explore the impact of impedance mismatch and loading conditions on spallation behavior and twin formation. It was found that the interfaces play a crucial role in the dynamic response of these multilayered systems since secondary reflection waves generated at the interfaces significantly affected the peak stress and pressure profiles, influencing void nucleation and failure modes. In the trilayer systems, failure predominantly occurred at interfaces and within the Ta layer, with void nucleation sites and twinning behavior being markedly different compared to single-crystal Cu and Ta. Increasing the Ta layer thickness modified the wave interactions, leading to different failure locations. Higher piston velocities were associated with increased spall strength by enhancing wave interactions and void formation, particularly at the interfaces and within the Ta layer, under specific configurations. Additionally, shorter shock pulse durations facilitated earlier initiation of the release fan, reducing twin formation and altering the failure dynamics by accelerating twin annihilation and pressure release.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Modeling deformation and failure in AlSi-polyester abradable sealcoating material using microstructure-based finite element simulation

A plasma-sprayed aluminum-silicon (AlSi)/polyester coating is applied in modern gas turbine engines as an abradable sealcoating to maintain tight clearances between the rotating blades and the static casing. While running the engine, the rotating blades “rub” with the abradable coating, which results in extreme strain rate (up to 10 6 ) dynamics and a high-temperature environment. Due to the difficulty of collecting direct measurements, predictive computational models are important for analyzing the deformation and failure of the abradable material, to help meet the design target of avoiding damage to the blade tip and maintaining high fuel efficiency. In this research, a microstructure-based finite element (FE) computational model was developed to capture the complex mechanical behavior of the AlSi/polyester microstructure. The model is based on a virtual representative-volume-element (RVE) of a metal-polymer microstructure, reconstructed from x-ray computed tomography. It models the plastic deformation of, and damage to, each AlSi and polyester constituents, as well as the failure at their interface. The model was calibrated and validated with uniaxial tension and compression experiments, conducted at two temperatures (298 K and 533 K) at an applied strain rate of 10 3 - 10 4 s -1 . The material exhibited strongly asymmetric tension-compression behavior and a sensitivity to temperature, which was well captured by the model. The model was further applied to investigate changes in mechanical behavior due to variations in constituents’ volume fractions, which provides guidance to the microstructural design of AlSi/polyester abradable materials. The model is expected to facilitate the development of improved abradable materials by bypassing the conventional trial-and-error approach and extensive testing requirements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Reduced partitioning of plastic strain for strong and yet ductile precipitate-strengthened alloys

When a material that contains precipitates is deformed, the precipitates and the matrix may strain plastically by different amounts causing stresses to build up at the precipitate-matrix interfaces. If premature failure is to be avoided, it is therefore essential to reduce the difference in the plastic strain between the two phases. Here, we conduct nanoscale digital image correlation to measure a new variable that quantifies this plastic strain difference and show how its value can be used to estimate the associated interfacial stresses, which are found to be approximately three times greater in an Fe-Ni 2 AlTi steel than in the more ductile Ni-based superalloy CMSX-4 ® . It is then demonstrated that decreasing these stresses significantly improves the ability of the Fe-Ni 2 AlTi microstructure to deform under tensile loads without loss in strength.

36 MATERIALS SCIENCE↗