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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

In-situ effect in cross-ply laminates under various loading conditions analyzed with hybrid macro/micro-scale computational models

In this article, multi-scale finite element analyses based on three-dimensional (3D) hybrid macro/micro-scale computational models subjected to various loading conditions are carried out to examine the in-situ effect imposed by the neighboring plies on the failure initiation and propagation of cross-ply laminates. A detailed comparative study on crack suppression mechanisms due to the effect of embedded laminar thickness and adjacent ply orientation is presented. Furthermore, we compare the results of in-situ transverse failure strain and strength between the computational models and analytical predictions. Good agreements are generally observed, indicating the constructed computational models are highly accurate to quantify the in-situ effect. Subsequently, empirical formulas for calculating the in-situ strengths as a function of embedded ply thickness and different ply angle between embedded and adjacent plies are developed, during which several material parameters are obtained using a reverse fitting method. Finally, a new set of failure criteria for σ 22 -τ 12 , σ 22 -τ 23 , and σ 11 -τ 12 accounting for the in-situ strengths are proposed to predict laminated composites failure under multi-axial stress states. This study demonstrates an effective and efficient computational technique towards the accurate prediction of the failure behaviors and strengths of cross-ply laminates by including the in-situ effects.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Experimental investigation of probabilistic failure of SiC/SiC composite tubes under multiaxial loading

This paper presents an experimental investigation of the failure behavior of SiC fiber-reinforced SiC matrix (SiC/SiC) composite tubes under multiaxial loading. A new testing apparatus is designed to independently apply axial stress and internal pressure to SiC/SiC tubes. Acoustic emission (AE) is used to monitor the damage growth in the specimen. Based on the measured stress–strain response, a strain-based criterion is proposed to determine the proportional limit stress (PLS). The proposed strain-based criterion is compared with the PLS determined by the AE measurement. The PLS is determined for different loading ratios to form a multiaxial failure surface. By testing multiple replicates, the statistical variations of the PLS are determined. In conclusion, based on the experimental results, a mathematical model is developed to characterize the probability distribution of the PLS of SiC/SiC composites under multiaxial loading.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Experimental workflow to estimate model parameters for evaluating long term viscoelastic response of CO2 storage caprocks

Understanding the time-dependent behavior of reservoir and sealing formations is critical to assessing risks associated with geological carbon storage since time-dependent deformation strongly influences mechanical responses of some rock types. Many studies have evaluated the risk of CO2 leakage and induced seismicity by assuming poroelastic rheology in sealing formations. Few have considered viscoelastic or other time-dependent responses, where the existing literature adopts 1D models to represent long-term time-dependent responses. This is primarily because to date, the general form of a reasonable 3D time-dependent model for rocks remains unclear. In this paper, we address this unclear issue by proposing a new workflow to select constitutive modeling parameters to evaluate if a 3D viscoelastic model is reasonable using several-hour-long experimental data and a power-law response to extrapolate to the decades-long time frames of interest in geologic carbon storage. To provide experimental data, we conducted multi-level loading/unloading triaxial relaxation tests with four rock types. The experimental results showed that the maximum load relaxation observed is approximately 49%, with some rock types showing as little as 1.4%. Using a simple linear viscoelastic model, parameters were chosen such that a maximum deviation of 1.5 MPa in axial stress and 7 MPa in radial stress was attained with the extrapolated 30-year data. We found that a reasonable parameter range for the normalized elastic modulus is 0.1~2 for rocks with significant time-dependent responses and 0.01~0.06 for those with small time-dependent responses. No matter how significant time-dependent responses are for rocks considered, our results showed that the relaxation time has a general range of 1~10^10 s, whose time scale can be one or two orders higher than a time frame typically envisioned for CO2 injection projects.

Stress relaxation, 3D time-dependent model, viscoe↗
DOE OSTI2017

Metal–Organic–Inorganic Nanocomposite Thermal Interface Materials with Ultralow Thermal Resistances

As electronic devices get smaller and more powerful, energy density of energy storage devices increases continuously, and moving components of machinery operate at higher speeds, the need for better thermal management strategies is becoming increasingly important. The removal of heat dissipated during the operation of electronic, electrochemical, and mechanical devices is facilitated by high-performance thermal interface materials (TIMs) which are utilized to couple devices to heat sinks. Here in this paper, we report a new class of TIMs involving the chemical integration of boron nitride nanosheets (BNNS), soft organic linkers, and a copper matrix -- which are prepared by chemisorption-coupled electrodeposition approach. These hybrid nanocomposites demonstrate bulk thermal conductivities ranging from 211 to 277 W/(m.K), which are very high considering their relatively low elastic modulus values on the order of 21.2 to 28.5 GPa. The synergistic combination of these properties lead to the ultra-low total thermal resistivity values in the range of 0.38 to 0.56 mm 2 .K/W for a typical bondline thickness of 30-50 um, advancing the current state-of-art transformatively. Moreover, its coefficient of thermal expansion (CTE) is 11 ppm/K, forming a mediation zone with a low thermally-induced axial stress due to its close proximity to the CTE of most coupling surfaces needing thermal management.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Measurement of elastic precursor decay in pre-heated aluminum films under ultra-fast laser generated shocks

Here, this article presents results from laser-driven shock compression experiments performed on pre-heated pure aluminum films at temperatures ranging from 23 to 400 °C. The samples were vapor deposited on the surface of a 500 μm thick sapphire substrate and mounted onto a custom holder with an integrated ring-heater to enable variable initial temperature conditions. A chirped pulse amplified laser was used to generate a pulse for both shocking the films and for probing the free surface velocity using Ultrafast Dynamic Ellipsometry. The particle velocity traces measured at the free surface clearly show elastic and plastic wave separation, which was used to estimate the decay of the elastic precursor amplitude over propagation distances ranging from 0.278 to 4.595 μm. Elastic precursors (which also correspond to dynamic material strength under uniaxial strain) of increasing amplitudes were observed with increasing initial sample temperatures for all propagation distances, which is consistent with expectations for aluminum in a deformation regime where phonon drag limits the mobility of dislocations. The experimental results show peak elastic amplitudes corresponding to axial stresses of over 7.5 GPa; estimates for plastic strain-rates in the samples are of the order 10 9 /s. The measured elastic amplitudes at the micron length scales are compared with those at the millimeter length-scales using a two-parameter model and used to correlate the rate sensitivity of the dynamic strength at strain-rates ranging from 10 3 to 10 9 /s and elevated temperature conditions. The overall trend, as inferred from the experimental data, indicates that the temperature-strengthening effect decreases with increasing plastic strain-rates.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Update on the Current R&D Activity in the U.S.

This presentation is to fulfil DOE commitment to GIF VHTR Materials PMB. Notched creep rupture testing: Weldment V-notch specimen test finished. 800C 60MPa, 15,716 hour rupture life. Two double V-notch specimen tests have finished. Crack growth tests: System modification was required for creep and creep-fatigue testing, Epsilon 3548COD Extensometer has been ordered, to allow load-line displacement measurements, to be paired with direct current potential drop already used to measure crack length, Sample redesigned in accordance to ASTM E2760 and E1457 to allow for both creep and creep-fatigue crack growth rate testing. Alloy 800H Weldments (1/2) and Alloy 800H Weldments (2/2), Variable Fatigue Testing, and Multi=axial Stress Relaxation. Continue work to finish 800H model, examine ?universal? constitutive model form.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Strain control of composite superconductors to prevent degradation of superconducting magnets due to a quench: II. High-strength, laminated Ag-sheathed Bi-2223 tapes

In article I of this series, we described a spiral coil quench technique for probing the influence of the superconductor stress and strain state during normal operation on its margin to degradation during a quench and applied to a Bi-2212 round wire. Here we extend this technique to study the failure mechanisms and limits of high-strength Bi-2223 tapes experiencing a quench while carrying a large current in a high magnetic field. In contrast to Bi-2212 magnets made via a wind-and-react technique for which bending strains can be ignored, Bi-2223 magnets are made with a react-and-wind technique for which bending strain is significant. The critical tensile stress of Bi-2223 tapes (type HT-NX) decreases from >440 MPa for straight samples to 185 MPa after being bent to a diameter D of 50 mm. For HT-NX tapes with D = 50 mm, the quench degradation limit, measured using maximum allowable temperature during a quench T allowable , is greater than 300 K for axial tensile stress ${\sigma }_{a}$ < 94 MPa; it decreases with increasing tensile axial stress ${\sigma }_{a}$ nonlinearly, dropping to 230 K for ${\sigma }_{a}$ = 125 MPa. T allow able $({\sigma }_{a})$ experimental data at D = 50 mm is consistently predicted by a general strain model that assumes that quench degradation in NX/Bi-2223 is driven by axial tensile strain in Bi-2223 filaments exceeding the irreversible strain limit. The T allowable $({\sigma }_{a})$ is then predicted for various D including D = 80 mm important for NMR magnets. In conclusion, the given T allowable $(D,{\sigma }_{a})$ is easy to use and important for finding the balance between operation stress, and therefore magnetic field generation efficiency, and operation margin when designing a superconducting magnet using Bi-2223 tapes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Computational Analysis of 3D Lattice Structures for Skin in Real-Scale Camber Morphing Aircraft

Conventional or fixed wings require a certain thickness of skin material selection that guarantees structurally reliable strength under expected aerodynamic loadings. However, skin structures of morphing wings need to be flexible as well as stiff enough to deal with multi-axial structural stresses from changed geometry and the coupled aerodynamic loadings. Many works in the design of skin structures for morphing wings take the approach either of only geometric compliance or a simplified model that does not fully represent 3D real-scale wing models. Thus, the main theme of this study is (1) to numerically identify the multi-axial stress, strain, and deformation of skin in a camber morphing wing aircraft under both structure and aerodynamic loadings, and then (2) to show the effectiveness of a direct approach that uses 3D lattice structures for skin. Various lattice structures and their direct 3D wing models have been numerically analyzed for advanced skin design.

Alsaidi, Bashir↗
DOE OSTI2018

Tracing the Pathway from Drift-Wave Turbulence with Broken Symmetry to the Production of Sheared Axial Mean Flow

This study traces the emergence of sheared axial flow from collisional drift-wave turbulence with broken symmetry in a linear plasma device—the controlled shear decorrelation experiment. As the density profile steepens, the axial Reynolds stress develops and drives a radially sheared axial flow that is parallel to the magnetic field. Results show that the nondiffusive piece of the Reynolds stress is driven by the density gradient, results from spectral asymmetry of the turbulence, and, thus, is dynamical in origin. Taken together, these findings constitute the first simultaneous demonstration of the causal link between the density gradient, turbulence, and stress with broken spectral symmetry and the mean axial flow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Generation of parasitic axial flow by drift wave turbulence with broken symmetry: Theory and experiment

Detailed measurements of intrinsic axial flow generation parallel to the magnetic field in the controlled shear decorrelation experiment linear plasma device with no axial momentum input are presented and compared to theory. The results show a causal link from the density gradient to drift-wave turbulence with broken spectral symmetry and development of the axial mean parallel flow. As the density gradient steepens, the axial and azimuthal Reynolds stresses increase and radially sheared azimuthal and axial mean flows develop. A turbulent axial momentum balance analysis shows that the axial Reynolds stress drives the radially sheared axial mean flow. The turbulent drive (Reynolds power) for the azimuthal flow is an order of magnitude greater than that for axial flow, suggesting that the turbulence fluctuation levels are set by azimuthal flow shear regulation. The direct energy exchange between axial and azimuthal mean flows is shown to be insignificant. Therefore, the axial flow is parasitic to the turbulence-zonal flow system and is driven primarily by the axial turbulent stress generated by that system. The non-diffusive, residual part of the axial Reynolds stress is found to be proportional to the density gradient and is formed due to dynamical asymmetry in the drift-wave turbulence.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Strain control of composite superconductors to prevent degradation of superconducting magnets due to a quench: I. Ag/Bi2Sr2CaCu2Ox multifilament round wires

The critical current of many practical superconductors is sensitive to strain, and this sensitivity is exacerbated during a quench that induces a peak local strain which can be fatal to superconducting magnets. Here, a new method is introduced to quantify the influence of the conductor stress and strain state during normal operation on the margin to degradation during a quench, as measured by the maximum allowable hot spot temperature T allowable, for composite wires within superconducting magnets. The first conductor examined is Ag-sheathed Bi2Sr2CaCu2Ox round wire carrying high engineering critical current density, J E, of 550 A mm−2 at 4.2 K and 15 T. The critical axial tensile stress of this conductor is determined to be 150 MPa and, in the absence of Lorentz forces, T allowable is greater than 450 K. With increasing axial tensile stress, σ a, however, T allowable decreases nonlinearly, dropping to 280 K for σ a = 120 MPa and to 160 K for σ a = 145 MPa. T allowable(σ a) is shown to be nonlinear and independent of magnetic field from 15 to 30 T. T allowable(σ a) dictates the balance between magnetic field generation, which increases with the magnet operating current and stress, and the safety margin, which decreases with decreasing T allowable, and therefore has important engineering value. It is also shown that T allowable(σ a) can be predicted accurately by a general strain model, showing that strain control is the key to preventing degradation of superconductors during a quench.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Threshold angle and valid fracture of the sectored flexural specimen

Here, the sectored flexural specimen was developed over a decade ago to measure the strength of ceramic and glass tubes and cylinders in which flaws on a tube's or cylinder's outer surface are limiters of axial tensile failure stress. Using the specimen's geometry, the associated axial tensile failure stress can be analytically calculated from the failure force measured from simple uniaxial bending, and multiple specimens (and test data) can be harvested from a single tube or cylinder. The sector angles of specimens in previous studies were somewhat arbitrarily chosen and usually produced validly occurring fractures and data; however, if the angle used was too small (relative to the tube's or cylinder's geometry), then undesirable application–irrelevant edge–located failures resulted. To avoid such failures in specimen design, a threshold sector angle was identified to guide the selection of a minimum sector angle (and consequential cross section) for any arbitrary sector flexural specimen harvested from a tube or cylinder. If the sector angle of the specimen is larger than the threshold value, then fracture will not occur at a specimen's edge and the measured axial failure stress will be limited by surface–located flaws on the tube's or cylinder's outer surface.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In situ measurement of three-dimensional intergranular stress localizations and grain yielding under elastoplastic axial-torsional loading

The three-dimensional grain-averaged response of solid bar samples under non-proportional (NP) elastoplastic axial-torsional loading was investigated using in situ high energy diffraction microscopy (HEDM) and companion crystal plasticity finite element (CPFE) modeling. Important stress metrics including applied shear (σ θZ ) and axial (σ ZZ ) stress tensor components, stress and stress deviator tensor invariants (I 1 , J 2 , and J 3 ), von Mises equivalent stress (σ$^{grain}_{VM}$), maximum resolved shear stress (mRSS), stress triaxiality (η), and lode angle parameter ($\barθ$) values were tracked for ~300 grains under two different loading conditions: (1) Torsion-dominated loading (low NP) and (2) Tension-torsion loading (high NP) in equiatomic NiCoCr, a representative multicomponent face-centered cubic (FCC) superalloy. Overall, significant stress localizations existed within both samples as evidenced by the radial dependence of grain-resolved σ θZ , σ$^{grain}_{VM}$, and J 2 ; by comparison, I 1 , J 3 , η, and $\barθ$ metrics did not show discernible trends within the volume. These stress localizations reveal a complex interplay between axial and shear stress components (e.g., stress coupling) resulting in grain yielding near the sample surface largely driven by shear stress, whereas internal grain yielding was largely accommodated by axial stress. Grain-resolved stress localization trends were described well by the CPFE model, although some discrepancies in magnitude occurred, particularly for volumetric stress metrics (I 1 and η) due to initial type II residual stress distributions. The superposition of initial residual stress states onto CPFE grain-resolved data significantly improved model accuracy for η. This suggests that residual stresses more strongly influence the simulation of volumetric rather than deviatoric (yield) stress metrics.

36 MATERIALS SCIENCE↗
DOE OSTI2018

How shear increments affect the flow production branching ratio in CSDX

In this study, the coupling of turbulence-driven azimuthal and axial flows in a linear device absent magnetic shear (Controlled Shear Decorrelation Experiment) is investigated. In particular, we examine the apportionment of Reynolds power between azimuthal and axial flows, and how the azimuthal flow shear affects axial flow generation and saturation by drift wave turbulence. We study the response of the energy branching ratio, i.e., ratio of axial and azimuthal Reynolds powers, P z R / P y R , to incremental changes of azimuthal and axial flow shears. We show that increasing azimuthal flow shear decreases the energy branching ratio. When axial flow shear increases, this ratio first increases but then decreases to zero. The axial flow shear saturates below the threshold for parallel shear flow instability. The effects of azimuthal flow shear on the generation and saturation of intrinsic axial flows are analyzed. Azimuthal flow shear slows down the modulational growth of the seed axial flow shear, and thus reduces intrinsic axial flow production. Azimuthal flow shear reduces both the residual Reynolds stress (of axial flow, i.e., Π x z R e s ) and turbulent viscosity ( χ z D W ) by the same factor | < v y > ' | - 2 Δ x - 2 L n - 2 ρ s 2 c s 2 , where Δ x is the distance relative to the reference point where < v y > = 0 in the plasma frame. Therefore, the stationary state axial flow shear is not affected by azimuthal flow shear to leading order since < v z > ' ~ Π x z R e s / χ z D W .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2017

Study on the residual stress relaxation in girth-welded steel pipes under bending load using diffraction methods

This research is dedicated to the experimental investigation of the residual stress relaxation in girth-welded pipes due to quasi-static bending loads. Ferritic-pearlitic steel pipes are welded with two passes, resulting in a characteristic residual stress state with high tensile residual stresses at the weld root. Also, four-point bending is applied to generate axial load stress causing changes in the residual stress state. These are determined both on the outer and inner surfaces of the pipes, as well as in the pipe wall, using X-ray and neutron diffraction. Focusing on the effect of tensile load stress, it is revealed that not only the tensile residual stresses are reduced due to exceeding the yield stress, but also the compressive residual stresses for equilibrium reasons. Furthermore, residual stress relaxation occurs both parallel and perpendicular to the applied load stress.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Biaxial Creep Behavior of Nb-Modified Zircaloys

Zr-Nb alloys are used as cladding materials to encapsulate radioactive fuel in nuclear reactors. They possess excellent corrosion resistance at high temperatures making it possible to achieve high fuel burn-up directly increasing the thermal efficiency of the reactor. While they are commonly used in recrystallized (Rx) form in boiling water reactors, there is a need to understand the effect of cold work and stress relief (CWSR) on biaxial creep characteristics of these materials due to their use in pressurized water reactors. In this study, the biaxial creep behaviors of as-received Zr-Nb alloys, HANA and Zirlo, have been investigated at 500 and 400 0C respectively using internally pressurized tubing superimposed with axial load under varied hoop (s?) to axial (sz) stress ratios of 0 to 2 while monitoring both the axial and hoop strains using an LVDT and a laser telemetric extensometer respectively. The crystallographic textures and creep loci of these as-received Zr-Nb alloys have been evaluated to correlate with the previous studies on recrystallized HANA4 and CWSR Zircaloy-4. The creep locus of HANA4 was found to be unaffected by initial state (CWSR or Rx) and showed close correspondence to planar isotropy while the creep locus of CWSR Zirlo exhibited more resistance to axial deformation than diametrical as per CWSR Zircaloy4 reported earlier. These differences are shown to arise from grain shape anisotropy of CWSR Zirlo and Zircaloy4. The simulated creep loci using crystallite orientation distribution functions (CODFs) in conjunction with prism slip models, showed excellent agreement with experimental results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Biaxial Creep Behavior of Nb-Modified Zircaloys

Zirconium-niobium (Zr-Nb) alloys are used as cladding materials to encapsulate radioactive fuel in nuclear reactors. They possess excellent corrosion resistance at high temperatures making it possible to achieve high fuel burnup, directly increasing the thermal efficiency of the reactor. While they are commonly used in recrystallized (Rx) form in boiling water reactors, there is a need to understand the effect of cold work and stress relief (CWSR) on the biaxial creep characteristics of these materials due to their use in pressurized water reactors. In this study, the biaxial creep behaviors of as-received Zr-Nb alloys, HANA and Zirlo®, have been investigated at 500°C and 400°C, respectively, using internally pressurized tubing superimposed with axial load under varied hoop σθ to axial σz stress ratios of 0 to 2 while monitoring both the axial and hoop strains using a linear variable displacement transformer and a laser telemetric extensometer, respectively. The crystallographic textures and creep loci of these as-received Zr-Nb alloys have been evaluated to correlate with the previous studies on recrystallized HANA4 and CWSR Zircaloy-4. The creep locus of HANA4 was found to be unaffected by initial state (CWSR or Rx) and showed close correspondence to planar isotropy while the creep locus of CWSR Zirlo exhibited more resistance to axial deformation than diametrical as per CWSR Zircaloy-4 reported earlier. These differences are shown to arise from grain-shape anisotropy of the CWSR Zirlo and Zircaloy-4. The simulated creep loci using crystallite-orientation distribution functions in conjunction with prism slip models showed excellent agreement with experimental results.

Tillman, Micah↗
DOE OSTI2017

Influences of Processing and Fatigue Cycling on Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

Oxidation and corrosion can attack superalloy disk surfaces exposed to increasing operating temperatures in some turbine engine environments. Any potential protective coatings must also be resistant to harmful fatigue cracking during service. The objective of this study was to investigate how residual stresses evolve in one such coating. Fatigue specimens of a powder metallurgy-processed disk superalloy were coated with a NiCrY coating, shot peened, and then subjected to fatigue in air at room and high temperatures. The effects of this processing and fatigue cycling on axial residual stresses and other aspects of the coating were assessed. While shot peening did induce beneficial compressive residual stresses in the coating and substrate, these stresses relaxed in the coating with subsequent heating. Several cast alloys having compositions near the coating were subjected to thermal expansion and tensile stress relaxation tests to help explain this response of residual stresses in the coating. For the coated fatigue specimens, this response contributed to earlier cracking of the coating than for the uncoated surface during long intervals of cycling at 760 °C. Yet, substantial compressive residual stresses still remained in the substrate adjacent to the coating, which were sufficient to suppress fatigue cracking there. The coating continued to protect the substrate from hot corrosion pitting, even after fatigue cracks initiated in the coating.

36 MATERIALS SCIENCE↗