Search NASA⌕ Search

SEARCH · Search NASA

Results for “Fatigue performance”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Crystallographic ordering of Al and Sn in α-Ti

Increasing attention is being paid to α (2) Ti 3 (Al,Sn) precipitation from the α phase of titanium alloys owing to its effect on slip band formation, localisation and the implications for fatigue performance in jet engine titanium. However, the early stages of α 2 precipitation have historically been difficult to observe by electron microscopy, neutron diffraction or atom probe analysis. Here, small angle X-ray scattering is used to reexamine the phase boundary in binary Ti-Al and Ti-Sn alloys with around 500 ppmw O. It is found that the phase boundaries in the literature are approximately correct, at 6.2 wt.% Al and 16.9 wt.% Sn, and that this favours the use of Al as a solid solution strengthener over Sn for ambient temperature applications. However, once O content and phase partitioning in α + β alloys are taken into account, this implies that Al eq limits for future alloy design of critical rotating parts should be lowered substantially.

36 MATERIALS SCIENCE↗
DOE OSTI2022

FAST Equipment Lease with Liberty University, Inc. (Cooperative Research and Development Final Report)

Liberty University, Inc. (Participant) will receive government owned equipment from NREL to evaluate and perform fatigue testing of bladders in use for small scale pumped storage hydropower. NREL is providing technical support to advance Liberty University's pumped storage hydropower (PSH) concept towards commercialization. The concept creates modular upper and lower watertight enclosures (tanks or reservoirs) connected by a series of modular pipe lengths (penstock).

13 HYDRO ENERGY↗
DOE OSTI2025

Cost Effectiveness of Laser Powder Bed Fusion for Heavy Duty Applications

ORNL (Contractor) and Cummins Inc. (Participant) collaborated to determine the cost effectiveness of laser powder bed fusion (LPBF) for heavy duty applications. The team demonstrated that coupons can be fabricated with two distinct process parameters i.e., different process parameters for the bulk and surface of the material. This is important for enabling the manufacturing of components in a production environment where the bulk of the material can be processed rapidly while high quality surface finish can minimize post-process machining as well as enable superior fatigue performance if the material were to be used in as-deposited condition.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Nitinol Electroslag Remelting: Initial Slag Study

Nitinol’s unique shape memory and super-elastic properties make it attractive for many applications in biomedical, automotive, aerospace, industrial refrigeration, and waste heat reclamation industries. The fatigue performance is limited however, by non-metallic inclusions (NMI) formed during the traditional VIM/VAR or multi-VAR process. ESR is a potential alternative melt process and is commonly used to refine ingot chemistry and enhance the metallurgical structure of many superalloys and specialty steels, but no study on ESR of Nitinol has been reported to date. The key to establishing a successful ESR process is selecting a compatible slag. In this study, several different slag chemistries are evaluated for their compatibility with Nitinol. One slag chemistry is chosen, along with a control, to produce four Nitinol ESR ingots. Pursuit of a novel slag chemistry for adequate Nitinol refinement is discussed.

Fezi, Kyle↗
DOE OSTI2025

Microstructure-Based Understanding of High-Temperature Deformation Behaviors in Laser Powder Bed Fusion (LPBF) 316H Stainless Steel

This report presents the results of high-temperature mechanical property testing and microstructural analysis of laser powder bed fusion (LPBF) 316H stainless steel (SS) conducted during Fiscal Year 2025 (FY25) under the U.S. Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program. The study builds upon prior work by expanding the mechanical property test matrix and advancing a microstructure-based mechanistic understanding of LPBF 316H SS performance, with a focus on the solution annealed (SA, 1100°C for 1 hour) materials. High-temperature tension, creep, fatigue, and creep-fatigue tests were performed. Thermal aging studies were conducted. Advanced characterization techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and high-energy synchrotron X-ray diffraction, were employed to investigate the microstructural evolution during thermal aging and mechanical testing. It was discovered that the as-built (AB) LPBF 316H SS exhibited precipitation kinetics during thermal aging that are 10–100 times faster than its wrought counterpart due to the presence of high densities of preferred nucleation sites, while the precipitation kinetics in SA LPBF 316H was under investigation. The accelerated precipitation of embrittling phases such as sigma phase in LPBF 316H SS compared to its wrought counterpart led to significant impacts on creep ductility. The influence of laser printing parameters and build orientations on fatigue and creep-fatigue performance was observed. In assessing the creep-fatigue performance, it was discovered that the SA LPBF 316H samples failed in less than 200 cycles under 595°C, 0.5% (strain amplitude) with a 60-minute hold time. This work establishes a mechanistic framework for predicting the long-term behavior of LPBF 316H SS, supporting its rapid qualification under the ASME BPVC. The findings contribute to the broader goal of enabling the deployment of advanced materials in next-generation nuclear energy systems. An outlook for FY26 work, including continued aging studies, mechanical testing, and microstructural characterization, is provided.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Radiation Damage Studies on Titanium Alloys as High Intensity Proton Accelerator Beam Window Materials

A high-strength dual a+ß phase titanium alloy Ti–6Al–4V is utilized as a material for beam windows in several accelerator target facilities. However, relatively little is known about how material properties of this alloy are affected by high-intensity proton beam irradiation. With plans to upgrade neutrino facilities at J-PARC and Fermilab to over 1 MW beam power, the radiation damage in the window material will reach a few displacements per atom (dpa) per year, significantly above the ~0.3 dpa level of existing data. The international RaDIATE collaboration, Radiation Damage In Accelerator Target Environments, has conducted a high intensity proton beam irradiation of various target and window material specimens at Brookhaven Linac Isotope Producer (BLIP) facility, including a variety of titanium alloys. Post-Irradiation Examination (PIE) of the specimens in the 1st capsule, irradiated at up to 0.25 dpa, is in progress. Tensile tests in a hot cell at Pacific Northwest National Laboratory (PNNL) exhibited a clear signature of radiation hardening and loss of ductility for Ti–6Al–4V, while Ti–3Al–2.5V, with less ß phase, exhibited less severe hardening. Microstructural investigations will follow to study the cause of the difference in tensile behavior between these alloys. High-cycle fatigue (HCF) performance is critical to the lifetime estimation of beam windows exposed to a periodic thermal stress from a pulsed proton beam. The first HCF data on irradiated titanium alloys are to be obtained by a conventional bend fatigue test at Fermilab and by an ultrasonic mesoscale fatigue test at Culham Laboratory. Specimens in the 2nd capsule, irradiated at up to ~1 dpa, cover typical titanium alloy grades, including possible radiation-resistant candidates. These systematic studies on the effects of radiation damage of titanium alloy materials are intended to enable us not only to predict realistic lifetimes of current beam windows made of Ti–6Al–4V, but also to extend the lifetime by choosing a more radiation and thermal shock tolerant alloy with a preferable heat treatment, or even by developing new materials.

Titanium Alloy, Beam Window, Proton Beam, Radiatio↗
DOE OSTI2020

Tuning of Nacelle Feedback Gains for Floating Wind Turbine Controllers Using a Two-DOF Model

Designing a collective blade pitch controller for floating offshore wind turbines (FOWTs) poses unique challenges due to the interaction of the controller with the dynamics of the platform. The controller must also handle the competing objectives of power production performance and fatigue load management. Existing solutions either detune the controller with the result of slowed response, make use of complicated tuning methods, or incorporate a nacelle velocity feedback gain. With the goal of developing a simple control tuning method for the general FOWT researcher that is easily extensible to a wide array of turbine and hull configurations, this last idea is built upon by proposing a simple tuning strategy for the feedback gain. This strategy uses a two degree-of-freedom (DoF) turbine model that considers tower-top fore-aft and rotor angular displacements. For evaluation, the nacelle velocity term is added to an existing gain scheduled proportional-integral controller as a proportional gain. The modified controller is then compared to baseline land-based and detuned controllers on an example system for several load cases. First-pass results are favorable, demonstrating how researchers can use the proposed tuning method to efficiently schedule gains for adequate controller performance as they investigate new FOWT configurations.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2025

Load assessment of a wind farm considering negative and positive yaw misalignment for wake steering

Wake steering strategies are employed to increase the overall power production of wind farms by deflecting wakes of upstream turbines away from downstream ones. The gain in net power comes at the expense of increased fatigue loads experienced by downstream turbines. In this work we investigate performance and fatigue loading characteristics of a small farm consisting of five aligned International Energy Agency Wind Technology Collaboration Programme 15 MW wind turbines. A parametric study is performed where, for every wind direction from −20 to 20°, the yaw misalignment angle varies from −25 to 25°. This setup allows us to investigate asymmetries and identify optimal conditions for a given wind direction. In general, we find that positive yaw configurations are preferred and that yaw configurations that result in attractive power differences when compared to a baseline no-yaw scenario (25 %) come with significant increase in fatigue loading (we use the standard deviation and damage-equivalent load (DEL) of the blade-root, low-speed shaft, and tower-base moments as proxies for fatigue load). We find that for any given positive wind inflow angle, yaw angles between −2.5 and 15° yield power differences of 10 %–20 % over a no-yaw baseline, and positive yaw is preferred because of lower fatigue loading. For any given negative wind inflow angles, positive yaw also results in lower magnitudes of standard deviation and DEL for the channels investigated. A small power loss of up to 2 % is observed for some positive yaw angles under negative wind directions (as compared to symmetric negative yaw and positive wind cases), but improvements in terms of loads exceed 25 % and may be enough to justify a positive yaw configuration under negative winds as well. We show that such behavior can be explained by partial waking and the direction of the rotation of the rotor.

17 WIND ENERGY↗
DOE OSTI2021

PRISMS-Fatigue computational framework for fatigue analysis in polycrystalline metals and alloys

Abstract The PRISMS-Fatigue open-source framework for simulation-based analysis of microstructural influences on fatigue resistance for polycrystalline metals and alloys is presented here. The framework uses the crystal plasticity finite element method as its microstructure analysis tool and provides a highly efficient, scalable, flexible, and easy-to-use ICME community platform. The PRISMS-Fatigue framework is linked to different open-source software to instantiate microstructures, compute the material response, and assess fatigue indicator parameters. The performance of PRISMS-Fatigue is benchmarked against a similar framework implemented using ABAQUS. Results indicate that the multilevel parallelism scheme of PRISMS-Fatigue is more efficient and scalable than ABAQUS for large-scale fatigue simulations. The performance and flexibility of this framework is demonstrated with various examples that assess the driving force for fatigue crack formation of microstructures with different crystallographic textures, grain morphologies, and grain numbers, and under different multiaxial strain states, strain magnitudes, and boundary conditions.

Chemistry↗
DOE OSTI2025

Effect of Fatigue on the Capacity and Performance of Structural Concrete

The goal of this project was to enhance the understanding of the fatigue behavior of concrete structures for the purpose of improving the design and assessment of towers and foundations that support wind turbines, which must endure repeated loadings from wind, waves, operations, and other dynamic effects that cause material degradation. This was achieved through physical experiments, a review of the technical literature, and collaboration with experts in key subject areas. The project produced a comprehensive database of publicly available fatigue data, several technical papers presenting the research findings, and two Technotes to be published by the American Concrete Institute that advance best practices in fatigue testing and enable the development of concrete-specific fatigue (S-N) (stress-life) curves. These contributions are expected to enhance the durability and cost-effectiveness of wind turbine support structures.

17 WIND ENERGY↗
DOE OSTI2025

Strain-rate hardening enhances fatigue resistance of AlSi10Mg alloy at 350°C

The high cycle fatigue behavior of laser powder bed fusion processed AlSi10Mg has been investigated at 350 °C (T/T m ∼ 0.7). The alloy exhibited a fatigue strength of 30 MPa defined by runout after 10 7 cycles at a conventional loading frequency of 20 Hz, corresponding to a notable fatigue strength to ultimate tensile strength ratio of 0.73. The surprising fatigue resistance was attributed to the strain-rate hardening effect at high fatigue loading frequency relative to tensile loading rates at 350 °C. The strain-rate hardening effect was validated by performing ultrasonic fatigue tests (20 kHz loading frequency) with three orders of magnitude higher strain-rates than those at conventional loading frequency. The higher strain-rates in ultrasonic fatigue increased the magnitude of strain-rate hardening resulting in longer AlSi10Mg fatigue lives compared to fatigue at conventional frequency, thus confirming the strain-rate hardening effect. The fatigue crack initiation mechanism was strain-rate dependent. Post-mortem microstructural examination revealed intergranular cavitation inside clusters of fine equiaxed grains. The cavities interlinked with each other to initiate near-surface fatigue cracks at conventional frequency. Cavitation occurred to a lesser extent at the ultrasonic frequency. As a result, fatigue cracks initiated at pre-existing processing defects near the surface in ultrasonic fatigue samples. Finally, this investigation underscores the role of fine grain clusters in promoting high-temperature fatigue crack initiation and indicates a possible trade-off between printability via grain refinement and high-temperature fatigue resistance of additively manufactured alloys.

Additive manufacturing↗
DOE OSTI2024

Estimation of the Thermal-Fluids and Thermal-Structural Performance of Helium-Cooled Modular Finger-Type Divertors

Over the past decade, our group has investigated the thermal-fluid performance of the helium-cooled modular divertor with multiple jets (HEMJ) and a simplified “flat” design of the HEMJ for long-pulse magnetic fusion energy (MFE) reactors. Experimental studies were performed in a helium (He) loop at the prototypical pressure of 10 MPa, nearly prototypical He temperatures and incident heat fluxes using test sections made from stainless steel and tungsten alloys. Correlations for average Nusselt numbers and pressure loss coefficients were developed from the data and are used to validate computational fluid dynamics (CFD) models. Here, this work presents updated thermal-fluids performance curves based on these correlations that estimate the maximum heat flux that can be accommodated by the plasma-facing surface and coolant pumping power requirements at prototypical operating conditions. Thermal-structural performance curves developed from ITER structural design criteria are introduced, which include protection against ductile and non-ductile failure, ratcheting fatigue, and creep fatigue. The performance design curves for these finger-type divertors demonstrate that the “flat” design, with a significantly less complicated geometry than the HEMJ, has thermal-fluid and thermal-structural performance comparable to the original HEMJ concept, and may be superior in terms of non-ductile failure criteria.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

An implantable biomechanical energy harvester for animal monitoring devices

Insufficient service life and the resulting need for battery replacements have been a great challenge for implantable electronic devices. This is particularly true for animal tracking applications, because recapturing animals is often unlikely once they are released to the wild. To tackle this problem, we developed a biomechanical energy harvester that uses a Macro Fiber Composite™ (MFC) piezoelectric beam to harvest the mechanical energy from animals’ body bending movements as the power source for implantable and wearable devices. Prototypes of an underwater acoustic transmitter using this technology were subdermally implanted into juvenile white sturgeon and their energy harvesting performance was evaluated through the device’s transmissions. Additionally, the fish successfully recovered from the implantation surgery and freely swam inside a tank. The transmitter prototypes in the fish continually transmitted signals for a period up to 5 weeks. A benchtop test setup was also created to emulate the fish’s body bending, estimate the device’s energy harvesting performance in the live fish, and perform accelerated fatigue testing of the energy harvester by applying test parameters learned from a video study of the fish’s body movement and behavior characteristics. The gradual depolarization of the piezoelectric ceramic material in the MFC under cyclic mechanical loading was the main limiting factor for the life span of the energy harvester. Pathways for improvement are proposed to achieve long-term efficacy of powering implantable and wearable electronic devices.

42 ENGINEERING↗
DOE OSTI2023

Design and Scoping Tests on Alloy 617 Using Notched Specimen Geometry to Validate Methods for Multiaxial Stress Relaxation

In FY 2022, a development effort was initiated at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) to examine the multiaxial stress-relaxation behavior and multiaxial stress-state effect on the creep-fatigue (CF) performance for Alloy 617 at elevated temperatures. This effort supported the development of the design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5. In this work, two types of the notch specimen geometries were designed. An inelastic constitutive model was used to investigate the stress triaxiality and elastic follow-up effects on the notch specimens under CF deformation in the finite element (FE) simulations. The numerical study demonstrated that the stress triaxiality and elastic follow-up caused by the notches both play significant roles in the stress-relaxation behavior. In addition, Alloy 617 CF experiments were designed, and the testing on the notch specimens is ongoing. CF test failure data will be generated on the specimens with notches under various conditions in FY 2023, and the results will be used to validate methods for accounting for the multiaxial stress relaxation effect in the design code.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Wind Turbine Gust Load Alleviation with Active Flow Control

Large wind turbine rotors are becoming more common in utility-scale wind power, especially for offshore wind plants. However, the trend toward large rotors can be limited by their ability to manage dynamic and extreme loads. To provide a safety margin for the rotor design and avoid catastrophic events such as tower strikes, extreme loads need to be controlled. The objective of this study is to develop and evaluate a feedback control system to alleviate extreme loads and reduce blade deflections under gust events using active flow control devices. We also propose a modification in the turbine controller to achieve further reduction in extreme loads. The extreme load reductions are evaluated under gust wind conditions with direction changes according to the IEC standard. The effects of the gust alleviation controller on turbine performance and fatigue loads are investigated as well. With the deployment of the gust alleviation controller and modified turbine baseline controller, the extreme loads and deflections reduce by up to 23%. The energy captured by the turbine is not affected by the proposed gust alleviation controller. The fatigue loads of various wind turbine components are either reduced or remain unchanged.

17 WIND ENERGY↗
DOE OSTI2020

In Situ and Post-Mortem Characterizations of Ultrasonic Spot Welded AZ31B and Coated Dual Phase 590 Steel Joints

Ultrasonic spot welding using different welding conditions was applied to join dissimilar metals of galvanized DP590 steel and AZ31B magnesium sheets. In situ high-speed imaging, digital image correlation, and infrared thermography were utilized to quantitatively study the interfacial relative motion, surface indentation, and heat generation across the joint faying interface and the sheet/sonotrode interfaces under the welding condition of moderate welding power and short welding time. For welds made with high power and long welding time, lap shear tensile tests as well as fatigue tests were carried out. Different fracture modes were observed after the lap shear tensile tests and fatigue tests performed under different peak loads. Post-weld cross-sectional analysis with scanning electron microscopy coupled with energy dispersive X-Ray spectroscopy revealed the variation of morphology and chemical composition at the joint interface for welds made with different welding conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal Stability and Lattice Strain Evolution of High-Nb-Containing TiAl Alloy under Low-Cycle-Fatigue Loading

The micromechanical behavior and the effect of temperature on the micromechanical mechanism of high-Nb-containing TiAl alloy during low-cycle fatigue still remain uncertain. Herein, in situ and ex situ synchrotron-based high-energy X-ray (HEXRD) experiment results reveal that the gamma and omega(o) phases suffer compressive lattice strains but the lattice strain in the alpha(2) phase evolves from tensile to compressive during low-cycle fatigue at 900 degrees C. In addition, the three phases suffer compressive lattice strains during cooling to room temperature, which could result in larger compressive lattice strains in gamma and omega(o) phases and the change of the lattice strain state in the alpha(2) phase. The peak-broadening results show gamma recrystallization is dominant in the interrupted low-cycle-fatigue samples, whereas inhomogeneous deformation occurs in the failed low-cycle-fatigue samples. The performed synchrotron diffraction experiments offer a deeper insight into the phase transformations and micromechanism of TiAl alloy during low-cycle fatigue.

cyclic stress-strain behavior↗