Pyrolytic graphite.
Pyrolytic graphite production by thermal decomposition of hydrocarbon gas on heated surface, noting annealing, alloying and residual stresses
PYROLYTIC GRAPHITE↗
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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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Lamination residual strains and stresses in hybrid laminates
An investigation is conducted of the effects of hybridization on the magnitude of lamination residual stresses. Eight-ply graphite/Kevlar 49/epoxy and graphite/S-glass/epoxy laminates were studied. The same matrix resin was selected for all basic materials to ensure compatibility and uniform curing of the various plies. The specimens, with inserted strain gages and thermocouples, were subjected to curing and postcuring cycles in an autoclave. Subsequently, the specimens were subjected to a thermal cycle from room temperature to 444 K and down to room temperature. It was found that hydridizing reduces apparently residual strains and stresses in the graphite plies. However, these strains were not affected much by the type and degree of hybridization.
Daniel, I. M.↗
Tensile and flexural strength of non-graphitic superhybrid composites: Predictions and comparisons
Equations are presented and described which can be used to predict bounds on the tensile and flexural strengths of nongraphitic superhybrid (NGSH) composites. These equations are derived by taking into account the measured stress-strain behavior, the lamination residual stresses and the sequence of events leading to fracture. The required input for using these equations includes constituents, properties (elastic and strength), NGSH elastic properties, cure temperature, and ply stress influence coefficients. Results predicted by these equations are in reasonably good agreement with measured data for strength and for the apparent knees in the nonlinear stress-strain curve. The lower bound values are conservative compared to measured data. These equations are relatively simple and are suitable for use in the preliminary design and initial sizing of structural components made from NGSH composites.
Chamis, C. C.↗
Tensile and flexural strength of nongraphitic superhybrid composites - Predictions and comparisons
Equations are presented and described which can be used to predict bounds on the tensile and flexural strengths of nongraphitic superhybrid (NGSH) composites. These equations are derived by taking into account the measured stress-strain behavior, the lamination residual stresses and the sequence of events leading to fracture. The required input for using these equations includes constituent composites, elastic and strength properties, NGSH elastic properties, cure temperature, and ply stress influence coefficients. Results predicted by these equations are in reasonably good agreement with measured data for strength and for the apparent 'knees' in the nonlinear stress-strain curve. The lower bound values are conservative compared to measured data. These equations are relatively simple and should be suitable for use in the preliminary design and initial sizing of structural components made from NGSH composites.
Chamis, C. C.↗
Nanomechanical Characterization of Additive Manufactured GRCop-42 Alloy Developed by Directed Energy Deposition Methods
Propulsion applications such as combustion chambers and nozzles for liquid rocket engines require the use of unique materials with superior mechanical and thermal properties. GRCop-42(Cu-4 wt.% Cr-2 wt.% Nb) is one such candidate material developed by NASA and is now being manufactured using additive manufacturing (AM) techniques. AM offers a unique processing environment different from traditional metal fabrication processes. This study characterized the mechanical and structural properties of as-deposited and heat-treated GRCop-42manufactured with Blown Powder Directed Energy Deposition (BPD)based on preliminary testing. The materials were characterized using several techniques including surface profiling by laser microscopy, mechanical stiffness by instrumented indentation, crystal structure, residual stress measurements using XRD and residual XRD, and chemical composition and microstructural evaluation using SEM with EBSD. The results of the study are compared using the BPD techniques for samples in the as-deposited and heat-treated conditions.
GRCop-42↗
Ultrasonic analysis of cold-rolled aluminum
Shear wave refraction for ultrasonic detection of residual stress in cold-worked aluminum
RESIDUAL STRESS↗
Stress corrosion susceptibility of stress-coined fastener holes in aircraft structures
The cold working process of stress coining is used to provide fatigue improvement of fastener holes in aircraft structures. The cold working produces a radial flow of the metal. The residual stresses resulting from stress coining provide protection against fatigue damage by opposing the applied tensile stresses in service at the edge of the fastener hole. However, it is shown in this paper that in addition to the compressive stresses surrounding the stress coined hole, there are tensile stresses that result from the coining operation and that these residual tensile stresses can have a deleterious effect on the stress corrosion susceptibility of the postcoined structure.
Carter, A. E.↗
Post-build stress-relief optimization for laser powder bed fusion 316H stainless steel
Nuclear energy remains a critical component of a diversified and efficient energy portfolio, offering reliable, high-capacity, and low-carbon power. However, in the U.S., aging infrastructure and the slow qualification and deployment of advanced materials and manufacturing techniques hinder progress in next-generation reactor technologies. This study explores the application of laser powder bed fusion (LPBF) additive manufacturing for stainless steel 316H, with a focus on optimizing post-build heat treatments to enhance material properties for high-temperature nuclear applications. The research targets the optimization of stress-relief temperatures to alleviate postbuild residual stresses, ensuring improvements in the microstructural corelated properties. A series of microstructural and mechanical evaluations were performed on LPBF-printed SS-316H samples which were subjected to annealing at temperatures varying between 650 °C and 850 °C. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that increasing the heattreatment temperature accelerated dislocation recovery. Vickers microhardness measurements showed an initial reduction in values, followed by stabilization over extended durations at all the temperatures. While higher temperatures facilitated faster recovery, they also promoted carbide precipitation along grain and solidification cell boundaries, narrowing the safe processing window. In contrast, heat treatment at 650°C preserved the cellular substructure and enabled controlled carbide precipitation over time. In conclusion, these findings highlight the importance of time–temperature optimization and suggest that 650°C for up to 2 h provides the most favorable balance between recovery and carbide control for a stress-relief treatment.
316 stainless steel↗
Influence of stress interaction on the behavior of off-axis unidirectional composites
The yield function for plane stress of a transversely isotropic composite lamina consisting of stiff, linearly elastic fibers and a von Mises matrix material is formulated in terms of Hill's elastic stress concentration factors and a single plastic constraint parameter. The above are subsequently evaluated on the basis of observed average lamina and constituent response for the Avco 5505 boron epoxy system. It is shown that inclusion of residual stresses in the yield function together with the incorporation of Dubey and Hillier's concept of generalized yield stress for anisotropic media in the constitutive equation correctly predicts the trends observed in experiments. The incorporation of the strong axial stress interaction necessary to predict the correct trends in the shear response is directly traced to the high residual axial stresses in the matrix induced during fabrication of the composite.
Pindera, M. J.↗
Elastic-plastic finite element analyses of an unidirectional, 9 vol percent tungsten fiber reinforced copper matrix composite
Micromechanical modeling via elastic-plastic finite element analyses were performed to investigate the effects that the residual stresses and the degree of matrix work hardening (i.e., cold-worked, annealed) have upon the behavior of a 9 vol percent, unidirectional W/Cu composite, undergoing tensile loading. The inclusion of the residual stress-containing state as well as the simulated matrix material conditions proved to be significant since the Cu matrix material exhibited plastic deformation, which affected the subsequent tensile response of the composite system. The stresses generated during cooldown to room temperature from the manufacturing temperature were more of a factor on the annealed-matrix composite, since they induced the softened matrix to plastically flow. This event limited the total load-carrying capacity of this matrix-dominated, ductile-ductile type material system. Plastic deformation of the hardened-matrix composite during the thermal cooldown stage was not considerable, therefore, the composite was able to sustain a higher stress before showing any appreciable matrix plasticity. The predicted room temperature, stress-strain response, and deformation stages under both material conditions represented upper and lower bounds characteristic of the composite's tensile behavior. The initial deformation stage for the hardened material condition showed negligible matrix plastic deformation while for the annealed state, its initial deformation stage showed extensive matrix plasticity. Both material conditions exhibited a final deformation stage where the fiber and matrix were straining plastically. The predicted stress-strain results were compared to the experimental, room temperature, tensile stress-strain curve generated from this particular composite system. The analyses indicated that the actual thermal-mechanical state of the composite's Cu matrix, represented by the experimental data, followed the annealed material condition.
Sanfeliz, Jose G.↗
Effect of a Large Population of Seeded Alumina Inclusions on Crack Initiation and Small Crack Fatigue Crack Growth in Udimet 720 Nickel-Base Disk Superalloy
Crack initiation, crack coalescence and small crack growth behavior were monitored for over 400 seeded inclusions during interrupted low cycle fatigue testing conducted on the P/M Udimet 720 nickel disk alloy at 650°C. Two types of seeded alumina inclusions with average sizes of 54 μm and 122 μm were used in the study performed at varying loading conditions resulting in LCF lives ranging from 2,000 cycles to over 1,000,000 cycles. The fatigue behavior was sub-categorized into four groups. Visual maps detailing inclusion size/cycle history were developed. The effect of surface residual stresses on the fatigue life was also investigated.
Superalloys↗
Fatigue Crack Growth in Peened Friction Stir Welds
Friction stir welding induces residual stresses that accelerates fatigue crack growth in the weld nugget. Shot peening over the weld had little effect on growth rate. Laser peening over the weld retarded the growth rate: Final crack growth rate was comparable to the base, un-welded material. Crack tunneling evident from residual compressive stresses. 2195-T8 fracture surfaces were highly textured. Texturing makes comparisons difficult as the material system is affecting the data as much as the processing. Material usage becoming more common in space applications requiring additional work to develop useful datasets for damage tolerance analyses.
Forth, Scott C.↗
Improved damage tolerance of SiC-based nuclear fuel cladding with novel multi-layered SiC coating design at 1200 °C
Continuous SiC fibre reinforced SiC matrix composites (SiC f -SiC m ) with monolithic SiC outer coatings are considered as a damage-tolerant cladding design for loss of coolant accident (LOCA) conditions in light water reactors. However, monolithic SiC coatings are brittle and prone to catastrophic failure. In this study, a SiC f -SiC m cladding with a novel multi-layer SiC outer coating (11 sub-layers, ∼260 µm in total thickness) was investigated under C-ring compression at room temperature and 1200 °C in argon environment. Real-time synchrotron X-ray computed tomography (XCT) was employed to capture crack initiation and propagation processes. Compared to conventional monolithic SiC outer coatings, the multi-layer coating structure facilitated crack deflection and bifurcation enhancing its damage tolerance at both temperatures. Despite pre-existing surface cracks, claddings exhibited stable mechanical-performance at both temperatures. These initial cracks did not critically affect the failure processes as they were not aligned with the maximum stress direction. Furthermore, the microstructure, distribution of residual stresses, and local properties of individual components in the material were thoroughly characterized, and compared with open literature on conventional claddings with monolithic outer coatings. These results provide new insights into the failure mechanisms of multi-layer SiC coatings and offer guidance for the future design of accident-tolerant nuclear fuel claddings.
36 - MATERIALS SCIENCE↗
Comparison of Stress Relief Procedures for Cryogenic Aluminum Mirrors
The Infrared Multi-Object Spectrograph (IRMOS) is a facility instrument for the Kitt Peak National Observatory Mayall Telescope (3.8 meter) and an engineering prototype for a potential design for the Next Generation Space Telescope/Multi-Object Spectrograph. IRMOS is a low-to mid-resolution (R = lambda/delta-lambda = 300-3800), near-IR (0.8-2.5 micron) spectrograph which produces simultaneous spectra of approximately 100 objects in its 2.8 x 2.0 arcmin field of view using a commercial MEMS multimirror array device. The instrument operating temperature is 80 K and the design is athermal --- the optical bench and mirrors are machined from aluminum 6061-T651. In spite of its baseline mechanical stress relief, aluminum 6061-T651 harbors some residual stress, which, unless relieved during fabrication, may relieve and distort mirror figure to unacceptable levels at the operating temperature. Other cryogenic instruments using aluminum mirrors for both ground-based and space IR astronomy have employed a variety of heat treatment formulae, with mixed results. We present the results of a test program designed to empirically determine the best stress relief procedure for the IRMOS mirrors. Identical test mirrors with spherical and flat optical prescriptions are processed with five different heat treatment formulae from the literature and compared to samples with out any additional processing. After figuring via diamond turning, the mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for several thermal cycles. The heat treatment procedure for the mirrors that yielded the least and most repeatable change in figure error and radius is applied to the IRMOS mirror blanks. We correlate the results of our optical testing with heat treatment and metallographic data.
Ohl, Raymond G.↗
Effects of Forged Stock and Pure Aluminum Coating on Cryogenic Performance of Heat Treated Aluminum Mirrors
In spite of its baseline mechanical stress relief, aluminum 6061-T651 harbors some residual stress that may relieve and distort mirror figure to unacceptable levels at cryogenic operating temperatures unless relieved during fabrication. Cryogenic instruments using aluminum mirrors for both ground-based and space IR astronomy have employed a variety of heat treatment formulae, with mixed results. We present the results of an on-going test program designed to empirically determine the effects of different stress relief procedures for aluminum mirrors. Earlier test results identified a preferred heat treatment for flat and spherical mirrors diamond turned from blanks cut out of Al6061-T651 plate stock. Further tests have been performed on mirrors from forged stock and one set from plate stock coated with Alumiplate(TM) aluminum coating to measure the effect of these variables on cryogenic performance. The mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for three thermal cycles. We correlate the results of our optical testing with heat treatment and metallographic data.
Toland, Ronald↗
Effects of substrate bias and tilt on magnetron sputtered boron carbide films
Maintaining high density and good mechanical properties at oblique angles for magnetron sputtered amorphous boron carbide films remains a challenge. In this study, we investigate the effect of the substrate bias on density, residual stress, mechanical properties, and morphology of boron carbide films deposited via direct current magnetron sputtering with a full-face erosion magnetron source in a mixed Ar-Ne plasma. Results show that films deposited at oblique substrate tilt angles on substrates biased at -50 V possess significantly lower oxygen content, superior mechanical properties, and higher density compared to their electrically grounded counterparts. In conclusion, these enhancements observed at oblique angles, while promising, come at the cost of larger residual compressive stress and higher Ne incorporation in films.
Materials science↗
A Comprehensive Review on Finite Element Analysis of Laser Shock Peening
Laser shock peening (LSP) is a formidable cold working surface treatment that provides high-energy precision to enhance the mechanical properties of materials. This paper delves into the intricacies of the LSP process, offering insights into its methodology and the simulation thereof through the finite element method. This review critically examines various points, such as laser energy, overlapping of shots, effect of LSP on residual stress, effect of LSP on grain refinement, and algorithms for simulation extrapolated from finite element analyses conducted by researchers, shedding light on the nuanced considerations integral to this technique. As the significance of LSP continues to grow, the collective findings underscore its potential as a transformative technology for fortifying materials against mechanical stress and improving their overall performance and longevity. The discourse encapsulates the evolving landscape of the LSP, emphasizing the pivotal role played by finite element analysis in advancing our understanding and application of this innovative surface treatment.
36 MATERIALS SCIENCE↗
Multiscale Modeling of Ceramic Matrix Composites
Results of multiscale modeling simulations of the nonlinear response of SiC/SiC ceramic matrix composites are reported, wherein the microstructure of the ceramic matrix is captured. This micro scale architecture, which contains free Si material as well as the SiC ceramic, is responsible for residual stresses that play an important role in the subsequent thermo-mechanical behavior of the SiC/SiC composite. Using the novel Multiscale Generalized Method of Cells recursive micromechanics theory, the microstructure of the matrix, as well as the microstructure of the composite (fiber and matrix) can be captured.
ceramic matrix composites↗