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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2010

A New Methodology For In-Situ Residual Stress Measurement In MEMS Structures

In this paper, a new approach is presented for local residual stress measurement in MEMS structures. The newly proposed approach involves incremental focused ion beam (FIB) milling of annular trenches at material surface, combined with high resolution SEM imaging and Digital Image Correlation (DIC) analysis for the measurement of the strain relief over the surface of the remaining central pillar. The proposed technique allows investigating the average residual stress on suspended micro-structures, with a spatial resolution lower than 1 {mu}m. Results are presented for residual stress measurement on double clamped micro-beams, whose layers are obtained by DC-sputtering (PVD) deposition. Residual stresses were also independently measured by the conventional curvature method (Stoney's equation) on a similar homogeneous coating obtained by the same deposition parameters and a comparison and discussion of obtained results is performed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2011

In-Situ Measurements of Fabric Thickness Evolution During Draping

The paper presents results of experimental program aimed at measuring fabric thickening while draping. The thickness evolution is important factor in resin infusion manufacturing where the resultant composite thickness is not controlled. The measurements are conducted by means of laser distance sensors adapted to the picture frame testing. Several carbon fabrics of very different architectures have been tested. Additionally, the pretension of the carbon fabric due to the gripping has been estimated by means of digital image correlation technique and an attempt to discuss the results obtained on different set-ups is made.

36 MATERIALS SCIENCE↗
DOE OSTI2011

In situ nanomechanical testing in focused ion beam and scanning electron microscopes

The recent interest in size-dependent deformation of micro- and nanoscale materials has paralleled both technological miniaturization and advancements in imaging and small-scale mechanical testing methods. Here we describe a quantitative in situ nanomechanical testing approach adapted to a dual-beam focused ion beam and scanning electron microscope. A transducer based on a three-plate capacitor system is used for high-fidelity force and displacement measurements. Specimen manipulation, transfer, and alignment are performed using a manipulator, independently controlled positioners, and the focused ion beam. Gripping of specimens is achieved using electron-beam assisted Pt-organic deposition. Local strain measurements are obtained using digital image correlation of electron images taken during testing. Examples showing results for tensile testing of single-crystalline metallic nanowires and compression of nanoporous Au pillars will be presented in the context of size effects on mechanical behavior and highlight some of the challenges of conducting nanomechanical testing in vacuum environments.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Application of MMC model on simulation of shearing process of thick hot-rolled high strength steel plate

Shear operation is widely used as the first step in sheet metal forming to cut the sheet or plate into the required size. The shear of thick hot-rolled High Strength Steel (HSS) requires large shearing force and the sheared edge quality is relatively poor because of the large thickness and high strength compared with the traditional low carbon steel. Bad sheared edge quality will easily lead to edge cracking during the post-forming process. This study investigates the shearing process of thick hot-rolled HSS plate metal, which is generally exploited as the beam of heavy trucks. The Modified Mohr-Coulomb fracture criterion (MMC) is employed in numerical simulation to calculate the initiation and propagation of cracks during the process evolution. Tensile specimens are designed to obtain various stress states in tension. Equivalent fracture strains are measured with Digital Image Correlation (DIC) equipment to constitute the fracture locus. Simulation of the tension test is carried out to check the fracture model. Then the MMC model is applied to the simulation of the shearing process, and the simulation results show that the MMC model predicts the ductile fracture successfully.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Design for reliability of BEoL and 3-D TSV structures – A joint effort of FEA and innovative experimental techniques

Copper-TSVs for 3D-IC-integration generate novel challenges for reliability analysis and prediction, e.g. the need to master multiple failure criteria for combined loading including residual stress, interface delamination, cracking and fatigue issues. So, the thermal expansion mismatch between copper and silicon leads to a stress situation in silicon surrounding the TSVs which is influencing the electron mobility and as a result the transient behavior of transistors. Furthermore, pumping and protrusion of copper is a challenge for Back-end of Line (BEoL) layers of advanced CMOS technologies already during manufacturing. These effects depend highly on the temperature dependent elastic-plastic behavior of the TSV-copper and the residual stresses determined by the electro deposition chemistry and annealing conditions. That’s why the authors pushed combined simulative/experimental approaches to extract the Young’s-modulus, initial yield stress and hardening coefficients in copper-TSVs from nanoindentation experiments, as well as the temperature dependent initial yield stress and hardening coefficients from bow measurements due to electroplated thin copper films on silicon under thermal cycling conditions. A FIB trench technique combined with digital image correlation is furthermore used to capture the residual stress state near the surface of TSVs. The extracted properties are discussed and used accordingly to investigate the pumping and protrusion of copper-TSVs during thermal cycling. Moreover, the cracking and delamination risks caused by the elevated temperature variation during BEoL ILD deposition are investigated with the help of fracture mechanics approaches.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Novel scanning electron microscope bulge test technique integrated with loading function

Membranes and film-on-substrate structures are critical elements for some devices in electronics industry and for Micro Electro Mechanical Systems devices. These structures are normally at the scale of micrometer or even nanometer. Thus, the measurement for the mechanical property of these membranes poses a challenge over the conventional measurements at macro-scales. In this study, a novel bulge test method is presented for the evaluation of mechanical property of micro thin membranes. Three aspects are discussed in the study: (a) A novel bulge test with a Scanning Electron Microscope system realizing the function of loading and measuring simultaneously; (b) a simplified Digital Image Correlation method for a height measurement; and (c) an imaging distortion correction by the introduction of a scanning Moiré method. Combined with the above techniques, biaxial modulus as well as Young's modulus of the polyimide film can be determined. Besides, a standard tensile test is conducted as an auxiliary experiment to validate the feasibility of the proposed method.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Experimental study of cyclic creep and high-cycle fatigue of welded joints of St3 steel by the DIC technique

In the paper the mechanisms of plastic deformation and fracture of welded joints of steel St3 were investigated at high-cycle fatigue and cyclic creep by the digital image correlation (DIC) technique. The evolution of strain rate is studied for the following regions: base metal, HAZ, and fusion zone. This strain rate evolution can be considered as a mechanical response of material. Three stages of deformation evolution are shown: deformation hardening (I), fatigue crack initiation (II), and the last stage is related to main crack (III). Two criteria are offered to evaluate the current mechanical state of welded joints.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Weak-shock wave propagation in polymer-based particulate composites

Shock waves are common in polymer-based particulate composites that are subjected to intermediate to high-velocity impact loading. However, quantitative information on the spatial variation of stress, particle velocities, and energy dissipation during the formation and propagation of weak-shock waves is limited. In this paper, a systematic experimental study is conducted to understand the characteristics of weak-shocks in polymer-bonded particulate composites. Specimens made of polymer-bonded sugar were subjected to a projectile impact loading, at varying velocities, using a modified Hopkinson pressure bar apparatus. Full-field displacement and strains of the deformed samples were obtained with the help of an ultrahigh-speed imaging and digital image correlation technique. Using the full-field displacement data, the shock wave velocity, shock front thickness, and the full-field stress fields are calculated. From the spatial stress field and the strain rate data, the spatial energy dissipation profile is also estimated. The effect of impact velocity on the spatial stress profile, shock wave velocity, and energy dissipation are discussed.

42 ENGINEERING↗
DOE OSTI2023

Microstructure dependent shear localization in 316L SS

Shear localization is characterized by the concentration of plastic deformation within narrow bands of material and constitutes the precursor to failure in materials subjected to high strain rates. These bands have been observed experimentally, but classical continuum material models have not been able to fully capture their development. The aim of this research is to investigate the role of microstructural differences in the dynamic shear response of wrought and additively manufactured (AM) 316L SS. Compact Forced Simple Shear specimens for Digital Image Correlation (CFSS-DIC) of wrought and additively manufactured 316L SS were tested on a Split Hopkinson Pressure Bar (SHPB) in conjunction with infrared thermometry measurements. Results indicate that the microstructures of wrought and AM 316L SS exhibit differences that affect the shear response of this materials. In conclusion, CFSS-DIC samples tested on the SHPB did not exhibit recrystallization inside the shear region, fact confirmed by thermometry measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Full-field quantitative visualization of shock-driven pore collapse and failure modes in PMMA

The dynamic collapse of pores under shock loading is thought to be directly related to hot spot generation and material failure, which is critical to the performance of porous energetic and structural materials. However, the shock compression response of porous materials at the local, individual pore scale is not well understood. This study examines, quantitatively, the collapse phenomenon of a single spherical void in PMMA at shock stresses ranging from 0.4 to 1.0 GPa. Using a newly developed internal digital image correlation technique in conjunction with plate impact experiments, full-field quantitative deformation measurements are conducted in the material surrounding the collapsing pore for the first time. The experimental results reveal two failure mode transitions as shock stress is increased: (i) the first in situ evidence of shear localization via adiabatic shear banding and (ii) dynamic fracture initiation at the pore surface. Numerical simulations using thermo-viscoplastic dynamic finite element analysis provide insights into the formation of adiabatic shear bands (ASBs) and stresses at which failure mode transitions occur. Further numerical and theoretical modeling indicates the dynamic fracture to occur along the weakened material inside an adiabatic shear band. Finally, analysis of the evolution of pore asymmetry and models for ASB spacing elucidate the mechanisms for the shear band initiation sites, and elastostatic theory explains the experimentally observed ASB and fracture paths based on the directions of maximum shear.

42 ENGINEERING↗
DOE OSTI2026

Mechanics of pore array collapse and interaction in shock-compressed polymethyl methacrylate (PMMA)

Recent studies on dynamic pore collapse have revealed significant development of shear localization, which can lead to material failure in porous structures and hot spot generation in energetic materials. These findings have dramatically improved the understanding of failure mechanisms during pore collapse but also prompt further investigation of realistic porous materials. In particular, porous media consist of many pores and porous networks. Even in low-porosity materials, pores can form in close proximity during the manufacturing process, leading to the critical question of pore–pore interaction during collapse under dynamic loading conditions. This study investigates, via plate impact experiments coupled with high-speed internal digital image correlation and shadowgraphy techniques, the collapse of two pores in shock-compressed PMMA at stresses between 0.4 and 1 GPa. The results of these experiments provide new insights into shear localization in pore collapse, in addition to distinct interactions between pores. Shadowgraphy measurements reveal novel, direct visualization of shear band development and crack evolution from pore surfaces. Spacing between adiabatic shear bands is measured over a range of impact stresses and is predicted accurately by the Grady–Kipp model. Pore interactions are found to effect a transition in the impact stress threshold at which different failure mechanisms initiate and are also found to possibly influence preferential sites for shear cracking. Throughout the study, numerical and theoretical models are leveraged to understand shear localization behavior. The role of baroclinicity and wave interactions between the pores is used to elucidate interaction mechanisms between pores.

Lawlor, Barry P. [California Institute of Technolo↗
DOE OSTI2020

Mechanical design of the highly porous cuttlebone: A bioceramic hard buoyancy tank for cuttlefish

Cuttlefish, a unique group of marine mollusks, produces an internal biomineralized shell, known as cuttlebone, which is an ultra-lightweight cellular structure (porosity, ~93 vol%) used as the animal’s hard buoyancy tank. Although cuttlebone is primarily composed of a brittle mineral, aragonite, the structure is highly damage tolerant and can withstand water pressure of about 20 atmospheres (atm) for the species Sepia officinalis . Currently, our knowledge on the structural origins for cuttlebone’s remarkable mechanical performance is limited. Combining quantitative three-dimensional (3D) structural characterization, four-dimensional (4D) mechanical analysis, digital image correlation, and parametric simulations, here we reveal that the characteristic chambered “wall–septa” microstructure of cuttlebone, drastically distinct from other natural or engineering cellular solids, allows for simultaneous high specific stiffness (8.4 MN∙m/kg) and energy absorption (4.4 kJ/kg) upon loading. We demonstrate that the vertical walls in the chambered cuttlebone microstructure have evolved an optimal waviness gradient, which leads to compression-dominant deformation and asymmetric wall fracture, accomplishing both high stiffness and high energy absorption. Moreover, the distribution of walls is found to reduce stress concentrations within the horizontal septa, facilitating a larger chamber crushing stress and a more significant densification. Overall, the design strategies revealed here can provide important lessons for the development of low-density, stiff, and damage-tolerant cellular ceramics.

42 ENGINEERING↗
DOE OSTI2022

Advances in phosphor two-color ratio method thermography for full-field surface temperature measurements

We report thermographic phosphors can be employed for optical sensing of surface, gas phase, and bulk material temperatures through different strategies including the time-decay method, time-integrated method, and frequency-domain method. We focus on the time-integrated method, also known as the ratio method, as it can be more practical in many situations. This work advances the ratio method using two machine vision cameras with CMOS detectors for full-field temperature measurements of a solid surface. A phosphor calibration coupon is fabricated using aerosol deposition and employed for in situ determination of the temperature-versus-intensity ratio relationship. Algorithms from digital image correlation are employed to determine the stereoscopic imaging system intrinsic and extrinsic parameters, and accurately register material points on the sample to subpixel locations in each image with 0.07 px or better accuracy. Detector nonlinearity is carefully characterized and corrected. Temperature-dependent, spatial non-uniformity of the full-field intensity ratio—posited to be caused by a blue-shift effect of the bandpass filter for non-collimated light and/or a wavelength-dependent transmission efficiency of the lens—is assessed and treated for cases where a standard flat-field correction fails to correct the non-uniformity. In sum, pixel-wise calibration curves relating the computed intensity ratio to temperature in the range of T = 300–430 K are generated, with an embedded error of less than 3 K. This work offers a full calibration methodology and several improvements on two-color phosphor thermography, opening the door for full-field temperature measurements in dynamic tests with deforming test articles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Multi-solution nature of topology optimization and its application in design for additive manufacturing

The purpose of this paper is to introduce the multi-solution nature of topology optimization (TO) as a design tool for additive manufacturing (AM). The sensitivity of topologically optimized parts and manufacturing constraints to the initial starting point of the optimization process leading to structures with equivalent performance is explored. A modified bi-directional evolutionary structural optimization (BESO) code was used as the numerical approach to optimize a cantilever beam problem and reduce the mass by 50 per cent. Several optimized structures with relatively equivalent mechanical performance were generated by changing the initial starting point of the TO algorithm. These optimized structures were manufactured using fused deposition modeling (FDM). The equivalence of strain distribution in FDM parts was tested with the digital image correlation (DIC) technique and compared with that from the modified BESO code.The results confirm that TO could lead to a wide variety of non-unique solutions based on loading and manufacturability constraints. The modified BESO code was able to reduce the support structure needed to build the simple two-dimensional cantilever beam by 15 per cent while keeping the mechanical performance at the same level. Finally, the originality of this paper lies in introduction and application of the multi-solution nature of TO for AM as a design tool for optimizing structures with minimized features in the overhang condition and the need for support structures.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Assessment of the displacement field along a surface crack in a flat plate using optical techniques

Structural components may contain cracks, and for these components a crack tip represents a highly singular stress. The evaluation of the associated strain gradient is difficult to achieve with experimental discrete methods. An efficient alternative are the optical techniques which are non-contact, and so delivering continuous information of the displacement fields and associated derivatives for strain evaluation. This paper describes some experimental methods to fully characterize the displacement field near a crack tip existing in flat plates. Three optical field techniques based on image analysis were used in the present work; respectively, Electronic Speckle Pattern Interferometry, Moiré Interferometry, and Digital Image Correlation. These methods allow different resolutions which can be adjusted according to the expected strain gradient. While the first method depends on the laser wavelength and position of the illumination sources, the second depends on the grating pitch and the last on the surface texture or painted speckle. Algorithms to derivate and filtering the displacement field are developed to compute the strain field and will be used for further works.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Scalable measurements of tow architecture variability in braided ceramic composite tubes

Abstract The performance of braided ceramic matrix composites has been shown to depend on the spatial arrangement of tows; therefore, a new class of tools is required to measure irregularities in the composite architecture for components with intricate geometries. We report a scalable and robust reconstruction technique built upon stereoscopic digital image correlation that is able to efficiently measure the position of tows in arbitrarily shaped composites. This method was applied to triaxially braided ceramic matrix composite tubes intended for use as nuclear fuel cladding, which revealed both long‐range “systematic” tow packing defects associated with the manufacturing process and short‐range “intrinsic” defects due to the braid architecture. These findings suggested that the character of tow spacing variation in braided composite tubes was substantially more complex than in planar woven composites. These measurements are expected to lead to improved processing of braided composites and to facilitate the design of statistically representative virtual specimens for finite element modeling.

Heim, Frederick M.↗
DOE OSTI2020

Experimental Evaluation of Geopolymer, Nano-Modified, and Neat Class H Cement by Using Diametrically Compressive Tests

Abstract Cement is the prime barrier material to maintain zonal isolation during wellbore life-cycle. Different types of the cement have different performances on sealability. The primary objective of this study is evaluation of three types of cement systems, neat Class H, nano-synthetic graphite, and rock-based geopolymer cements, on interfacial bond integrity. Diametrical compressive tests are used on casing–cement–formation systems. Cement performances are tested in a conventional configuration (Berea Sandstone). A universal testing system is utilized to analyze the relationship applied load–axial strain and the digital image correlation (DIC) technique is used to generate the strain field maps. Based on the relationship and DIC results, bond strengths in different cement systems are evaluated. Additionally, microscope images provide insight explanations of the bond from micro-view. Based on the experimental results, failures of all cases initiate and propagate from the casing–cement interface. Then, radial cracks develop through the formation. This is because the mechanical interlocking bonds are formed only at the cement–sandstone interface to enhance the bond strength. The comparison of geopolymer and nano-modified cements with the conventional cement (neat Class H) shows that the unconventional cements have a lower maximum load and higher axial strain before failure of the samples. It indicates that both the two kinds of cements are more ductile than conventional cement and can support more deformation before the initiation of cracks.

Energy & Fuels↗
DOE OSTI2020

A Generalized Stress Inversion Approach With Application to Residual Stress Estimation

In this work develop a generalized stress inversion technique (or the generalized inversion method) capable of recovering stresses in linear elastic bodies subjected to arbitrary cuts. Specifically, given a set of displacement measurements found experimentally from digital image correlation (DIC), we formulate a stress estimation inverse problem as a partial differential equation-constrained optimization problem. We use gradient-based optimization methods, and we accordingly derive the necessary gradient and Hessian information in a matrix-free form to allow for parallel, large-scale operations. By using a combination of finite elements, DIC, and a matrix-free optimization framework, the generalized inversion method can be used on any arbitrary geometry, provided that the DIC camera can view a sufficient part of the surface. We present numerical simulations and experiments, and we demonstrate that the generalized inversion method can be applied to estimate residual stress.

42 ENGINEERING↗