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At least 451 records · Page 25

Development of Matrix Microstructures in UHTC Composites

One of the major issues hindering the use of ultra high temperature ceramics for aerospace applications is low fracture toughness. There is considerable interest in developing fiber-reinforced composites to improve fracture toughness. Considerable knowledge has been gained in controlling and improving the microstructure of monolithic UHTCs, and this paper addresses the question of transferring that knowledge to composites. Some model composites have been made and the microstructures of the matrix developed has been explored and compared to the microstructure of monolithic materials in the hafnium diboride/silicon carbide family. Both 2D and 3D weaves have been impregnated and processed.

Johnson, Sylvia↗

Al-Cu-Zn-Mg Alloy for Additive Manufacturing by Electron Beam Deposition

The application of fusion-based additive manufacturing (AM) to aircraft structural components is limited by the lack of high-strength aluminum alloys optimized for AM processing. High strength aluminum alloys (such as 7050-T7451) are difficult to process by AM because of their solidification cracking susceptibility and loss of volatile alloying elements such as Zn and Mg. The performance of a proprietary Al-Cu-Zn-Mg alloy wire feedstock was evaluated for AM utilizing electron beam deposition. Deposit microstructure, composition, occurrence of porosity and cracking, and post-heat treatment tensile and fracture toughness were correlated with deposition parameters. Post-heat treatment strength, ductility, and fracture toughness were lower than typical values for wrought 7050-T7451, related to significant losses of Zn and Mg and to porosity. Recommendations are offered for modifications to wire feedstock composition and adjustments to deposition conditions and heat treatment to enable AM of electron beam deposited material that has strength comparable to 7050-T7451 wrought products.

Al-Cu-Zn-Mg alloy, electron beam deposition, mecha↗

Fracture mechanics. II.

Fracture-toughness tests described to obtain fracture data for transformation into allowable design stresses

STRESS ANALYSIS↗

Measurement of crack length in width tapered beam experiments

The width tapered beam method for measuring fracture toughness has been contemplated for use in measuring the adhesion of photovoltaic materials, is promoted by it being a viable method for use directly on modules rather than to engineered test specimens. However, precise determination of crack length is often difficult as failure often involves tendril formation, cavitation voids, and other plastic deformation at the crack front in addition to obfuscation by opaque materials. Because fracture energy varies as the square of crack length, imprecise crack tip length results in large measurement uncertainties. In this work, we develop a method to estimate the crack tip length using the relationship between the applied force and the displacement of the load frame. The crack tip is determined for every data point and can be defined from a calibration curve related to the amount of energy put into the beam, or from a theoretically idealized estimation. Once a calibration curve is set up and the equations programmed, the fracture energy as a function of position on the newly formed crack interface can be accurately estimated. The test additionally provides much easier analysis and insight into the joint failure through more precise knowledge of fracture toughness at each de-bonded area.

42 ENGINEERING↗

Vacuum melting and mechanical testing of simulated lunar glasses

Lunar silicate glasses may possess superior mechanical properties compared to terrestrial glasses because the anhydrous lunar environment should prevent hydrolytic weakening of the strong Si-O bonds. This hypothesis was tested by melting, solidifying, and determining the fracture toughness of simulated mare and highlands composition glasses in a high vacuum chamber. The fracture toughness, K(IC), of the resulting glasses was obtained via microindentation techniques. K(IC) increased as the testing environment was changed from air to a vacuum of 10 exp -7 torr. However, this increase in toughness may not result solely from a reduction in the hydrolytic weakening effect; the vacuum-melting process produced both the formation of spinel crystallites on the surfaces of the glass samples and significant changes in the compositions which may have contributed to the improved K(IC).

Carsley, J. E.↗

Fracture Analysis of Particulate Reinforced Metal Matrix Composites

A fracture analysis of highly loaded particulate reinforced composites was performed using laser moire interferometry to measure the displacements within the plastic zone at the tip of an advancing crack. Ten castings were made of five different particulate reinforcement-aluminum alloy combinations. Each casting included net-shape specimens which were used for the evaluation of fracture toughness, tensile properties, and flexure properties resulting in an extensive materials properties data. Measured fracture toughness range from 14.1 MPa for an alumina reinforced 356 aluminum alloy to 23.9 MPa for a silicon carbide reinforced 2214 aluminum alloy. For the combination of these K(sub Ic) values and the measured tensile strengths, the compact tension specimens were too thin to yield true plane strain K(sub Ic) values. All materials exhibited brittle behavior characterized by very small tensile ductility suggesting that successful application of these materials requires that the design stresses be below the elastic limit. Probabilistic design principles similar to those used with ceramics are recommended when using these materials. Such principles would include the use of experimentally determined design allowables. In the absence of thorough testing, a design allowable stress of 60 percent of the measured ultimate tensile stress is recommended.

Min, James B.↗

Strength, toughness and R-curve behaviour of SiC whisker-reinforced composite Si3N4 with reference to monolithic Si3N4

The flexural strength and fracture toughness of 30 vol pct SiC whisker-reinforced Si3N4 material were determined as a function of temperature from 25 to 1400 C in an air environment. It was found that both strength and toughness of the composite material were almost the same as those of the monolithic counterpart. The room-temperature strength was retained up to 1100 C; however, appreciable strength degradation started at 1200 C and reached a maximum at 1400 C due to stable crack growth. In contrast, the fracture toughness of the two materials was independent of temperature with an average value of 5.66 MPa sq rt m. It was also observed that the composite material exhibited no rising R-curve behavior at room temperature, as was the case for the monolithic material. These results indicate that SiC whisker addition to the Si3N4 matrix did not provide any favorable effects on strength, toughness and R-curve behavior.

Choi, S. R.↗

Recent Advances in Pipeline Integrity for Transporting Blended Hydrogen-Natural Gas

To achieve US decarbonization goals, hydrogen is being considered as an alternative energy source to reduce carbon emissions. Blending hydrogen into existing natural gas pipelines is an intuitive first step to enable near term emission reductions. However, there are numerous challenges and uncertainties that complicate the transition to transporting hydrogen long-distance through existing natural gas pipelines. The main challenge is hydrogen embrittlement (HE), which reduces the ductility, fracture toughness and fatigue resistance of pipeline steels. This work delivers a technical review on HE effects on the material properties of pipeline carbon steels, such as Grade B, X52, X65, X70, X80, and X100. An important aspect of laboratory tests to capture the HE effect is the hydrogen test environment. This includes hydrogen pre-charged specimens tested in air and specimens tested in a hydrogen gas environment. A review of the mechanical properties of pipeline steel in different hydrogen environments determined through tensile testing is given first, which includes HE effects on yield strength, ultimate tensile strength, and ductility for blended hydrogen-natural gas pipelines. Then, the HE effects on fracture toughness and fatigue crack growth resistance are discussed. Last, impacts of HE to pipeline integrity and major technical challenges are discussed.

: Hydrogen Embrittlement↗

Comparison of Nb 3 Sn Insulation Systems With as Received and De-Sized Glass

Epoxy cracking has been the main suspected contributor to training in Nb 3 Sn magnets for some time, as it leads to energy release and magnet quenching. Cracking in a superconducting composite can occur from several modes, and the likelihood of these modes is not well understood. Failure has been observed between insulation systems and the superconducting cable itself rather than within the cable or insulation. To target the behavior at the interface, samples have been fabricated and tested for Mode I fracture toughness in an adapted version of ASTM D5528. This work seeks to better characterize the fracture toughness of this interface to better understand how to model and design insulation systems.

Krave, Steven T. [Fermilab] (ORCID:000000021752145↗

Mechanics of fracture - Fundamentals and some recent developments

An overview is presented of the fundamental aspects of and recent developments in fracture mechanics. Reference is made to linear elastic fracture mechanics including the state of stresses and displacements in the vicinity of cracks, effects of crack geometry and orientation on stress intensity factors, energy balance of Griffith, Irwin's stress intensity concept, and linear elastic fracture mechanics testing for fracture toughness. Other aspects of this paper include the non-linear behavior of materials and their influence on fracture mechanics parameters, consideration of viscoelasticity and plasticity, non-linear fracture toughness parameters as C.O.D., R-curve and J-integral, and a non-linear energy method, proposed by Liebowitz. Finite element methods applied to fracture mechanics problems are indicated. Also, consideration has been given to slow crack growth, dynamic effects on K(IC), Sih's criterion for fracture, Lee and Liebowitz's criterion relating crack growth with plastic energy, and applications of fracture mechanics to aircraft design. Suggestions are offered for future research efforts to be undertaken in fracture mechanics.

Liebowitz, H.↗

Analysis of attenuation data from the decommissioned ZIon unit 1 reactor pressure vessel beltline weld

In order to examine the attenuation of radiation damage through the thickness of an irradiated reactor pressure vessel (RPV), four segments were acquired from the Zion Unit 1 power plant RPV after the plant was decommissioned. The Zion Unit 1 RPV Beltline Weld Segment 1 was cut into seven blocks, consisting of five base metal and two beltline welds from the high fluence region of the segment. Through-wall test specimens were machined and tested. Specimens included those used for Charpy impact, Master Curve fracture toughness testing, and chemical analysis. The observed through-thickness ductile-to-brittle transition temperatures in the beltline weld deviated significantly from the expected behavior based on the attenuation of fast fluence as a function of depth into the RPV. Beginning at the inside surface, the 41-J Charpy transition temperature was either flat or slightly increasing until the ¾ -T location. The results of a simple, model-based analysis of the Zion beltline weld material that included the irradiation conditions and material chemistry were generally consistent with industry trend curves and the standard attenuation model, rather than the observed data. Although there was no archive material from the RPV available to permit measurement of the unirradiated properties, fracture toughness specimens fabricated from archive surveillance weld were used to obtain an estimate of the initial through-thickness values of the Charpy transition temperature. The Charpy shifts obtained using this approach were similarly in disagreement with the predictions of the US NRC Regulatory Guide 1.99, Rev. 2. However, testing of irradiated Charpy specimens taken from the RPV following post-irradiation annealing (10 hr. at 500 °C) provided a quite different estimate of the unirradiated properties which improved the agreement between the inferred through-thickness Charpy shifts and exponential attenuation model included in Regulatory Guide 1.99/2. In conclusion, the analysis of the Zion data and data obtained in previous post-mortem examinations of decommissioned RPVs indicates that more work is needed to understand the through-thickness properties of RPV materials in order to properly assess through-wall damage attenuation.

Charpy impact↗

Insights into the soft brittle-to-ductile transition from discrete dislocation dynamics

The Brittle-to-ductile transition (BDT) in body centered cubic metals exhibits a soft transition wherein the fracture toughness gradually rises to before the onset of ductility. The resultant brittle-to-ductile transition temperature can be described with an Arrhenius relationship whose activation energy is related to plasticity in the material. To provide further insight into the nature of the BDTT, in this work we utilized a discrete dislo- cation dynamics model with a crack to simulate the BDT and how it depends on the thermally activated nature of plasticity. The interrelationship between the BDT activation energy and the dislocation mobility parameters were determined via the calculation of first order sensitivity coefficients. This analysis allows us to demonstrate that the activation energy for the BDT is directly related to the activation energy for plasticity through an effective stress that defines this relationship. This effective stress physically is the average stress on the dislocations that move out of the crack. Lastly, we are able to show that this effective stress is dictated by the low temperature fracture toughness or cleave energy of the material and the source position, the latter of which can be affected by processing. Collectively, these results provide new insight into what controls the thermal activation of the BDT and what are the important parameters to control it.

36 MATERIALS SCIENCE↗

Recent advances in the mechanical characterization of shales at nano-to micro-scales: A review

Understanding geomechanical properties of shales, such as stiffness properties and fracture toughness, is important in different areas of petroleum industry-related activities. Nanoscale to microscale experiments on shale samples require a much smaller sample compared to macroscale experiments. This is a major advantage because irregularly-shaped drill cuttings from shales can be used for experimental analyses, such as nanoindentation or atomic force microscopy (AFM). However, characterization of mechanical properties at the nano- to micro-scale is a relatively new addition to classical geomechanical experiments on shales, and there is still a lack of both fundamental knowledge and standard procedures for conducting experiments at this scale. The theoretical principles of nanoindentation-based (Gridded Nanoindentation and Modulus Mapping) and AFM-based experimental methods (PeakForce QNMTM and AFM-IR), a review of the literature results and the major findings are explained in Sections 2 and 3, respectively. These experimental techniques are compared in Section 4. Overall, nanoindentation experiments reveal the anisotropy of organic matter (OM)-rich shales at the nanoscale, and it is shown that gridded nanoindentation is capable of characterizing different minerals with respect to their stiffness properties. The capability of AFM (PeakForce QNMTM) to differentiate between different minerals within OM-rich shales with distinct mechanical properties, in particular stiffness, is also demonstrated. It is shown that AFM-based methods are more straightforward than gridded-nanoindentation to characterize OM-rich shales based on the stiffness of different constituent minerals of OM-rich shales, but nanoindentation can apply higher loads than AFM-based methods. Therefore, they can measure creep properties and fracture toughness of OM-rich shales. Here, it is shown that the OM is the most compliant part of the OM-rich shales, but it is still unclear if thermal maturation has an impact on the stiffness of OM. It is necessary to investigate if there is a relationship between the OM type (kerogen, bitumen, etc.) and mechanical properties such as Young’s modulus and Creep rate.

36 MATERIALS SCIENCE↗

Elevated temperature crack growth in advanced powder metallurgy aluminum alloys

Rapidly solidified Al-Fe-V-Si powder metallurgy alloy FVS0812 is among the most promising of the elevated temperature aluminum alloys developed in recent years. The ultra fine grain size and high volume fraction of thermally stable dispersoids enable the alloy to maintain tensile properties at elevated temperatures. In contrast, this alloy displays complex and potentially deleterious damage tolerant and time dependent fracture behavior that varies with temperature. J-Integral fracture mechanics were used to determine fracture toughness (K sub IC) and crack growth resistance (tearing modulus, T) of extruded FVS0812 as a function of temperature. The alloy exhibits high fracture properties at room temperature when tested in the LT orientation, due to extensive delamination of prior ribbon particle boundaries perpendicular to the crack front. Delamination results in a loss of through thickness constraint along the crack front, raising the critical stress intensity necessary for precrack initiation. The fracture toughness and tensile ductility of this alloy decrease with increasing temperature, with minima observed at 200 C. This behavior results from minima in the intrinsic toughness of the material, due to dynamic strain aging, and in the extent of prior particle boundary delaminations. At 200 C FVS0812 fails at K levels that are insufficient to cause through thickness delamination. As temperature increases beyond the minimum, strain aging is reduced and delamination returns. For the TL orientation, K (sub IC) decreased and T increased slightly with increasing temperature from 25 to 316 C. Fracture in the TL orientation is governed by prior particle boundary toughness; increased strain localization at these boundaries may result in lower toughness with increasing temperature. Preliminary results demonstrate a complex effect of loading rate on K (sub IC) and T at 175 C, and indicate that the combined effects of time dependent deformation, environment, and strain aging may play a role. Fractography showed that microvoid coalescence was the microscopic mode of fracture in FVS0812 under all testing conditions. However, the nature of the microvoids varied with test temperature and loading rate, and is complex for the fine grain and dipersoid sizes of FVS0812.

Porr, William C., Jr.↗

Morphology and properties of amine terminated poly(arylene ether ketone) and poly(arylene ether sulfone) modified epoxy resin systems

Epoxy resin networks cured with DDS were modified by incorporating tough ductile thermoplastics such as the amine terminated polyether sulfones and amine terminated polyether ketones. Both linear copolymers were able to significantly improve the fracture toughness values at the 15 and 30 weight percent concentrations examined. These improvements in fracture toughness were achieved without any significant change in the flexural modulus.

Cecere, J. A.↗

3-D Mixed Mode Delamination Fracture Criteria - An Experimentalist's Perspective

Many delamination failure criteria based on fracture toughness have been suggested over the past few decades, but most only covered the region containing mode I and mode II components of loading because that is where toughness data existed. With new analysis tools, more 3D analyses are being conducted that capture a mode III component of loading. This has increased the need for a fracture criterion that incorporates mode III loading. The introduction of a pure mode III fracture toughness test has also produced data on which to base a full 3D fracture criterion. In this paper, a new framework for visualizing 3D fracture criteria is introduced. The common 2D power law fracture criterion was evaluated to produce unexpected predictions with the introduction of mode III and did not perform well in the critical high mode I region. Another 2D criterion that has been shown to model a wide range of materials well was used as the basis for a new 3D criterion. The new criterion is based on assumptions that the relationship between mode I and mode III toughness is similar to the relation between mode I and mode II and that a linear interpolation can be used between mode II and mode III. Until mixed-mode data exists with a mode III component of loading, 3D fracture criteria cannot be properly evaluated, but these assumptions seem reasonable.

Reeder, James R.↗

Hygrothermal influence on delamination behavior of graphite/epoxy laminates

The hygrothermal effect on the fracture behavior of graphite-epoxy laminates was investigated to develop a methodology for damage tolerance predictions in advanced composite materials. Several T300/934 laminates were tested using a number of specimen configurations to evaluate the effects of temperature and humidity on delamination fracture toughness under mode 1 and mode 2 loading. It is indicated that moisture has a slightly beneficial influence on fracture toughness or critical strain energy release rate during mode 1 delamination, but has a slightly deleterious effect on mode 2 delamination and mode 1 transverse cracking. The failed specimens are examined by SEM and topographical differences due to fracture modes are identified. It is concluded that the effect of moisture on fracture topography can not be distinguished.

Garg, A.↗

Hygrothermal influence on delamination behavior of graphite/epoxy laminates

The hygrothermal effect on the fracture behavior of graphite-epoxy laminates was investigated to develop a methodology for damage tolerance predictions in advanced composite materials. Several T300/934 laminates were tested using a number of specimen configurations to evaluate the effects of temperature and humidity on delamination fracture toughness under mode 1 and mode 2 loading. It is indicated that moisture has a slightly beneficial influence on fracture toughness or critical strain energy release rate during mode 1 delamination, but has a slightly deleterious effect on mode 2 delamination, and mode 1 transverse cracking. The failed specimens are examined by SEM and topographical differences due to fracture modes are identified. It is concluded that the effect of moisture on fracture topography can not be distinguished.

Garg, A.↗