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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 OSTI2020

Neutron Diffraction Analysis of Residual Strain in High-Pressure Die Cast A383 Engine Blocks

The residual strains in three high-pressure die cast A383 engine blocks were measured using neutron diffraction. Residual strains and stresses can be generated during high-pressure die casting process due to high thermal gradients and may cause fatigue failure or dimensional distortion. Neutron diffraction can measure the residual strain distributions deep inside castings with complex geometries, because neutrons can penetrate substantially more material than x-rays. In this paper, the residual strains (in the axial and hoop directions) along the whole cylinder bridge of high-pressure die cast A383 engine blocks in as-cast and heat-treated conditions were measured by neutron diffraction methods. The effect of heat treatment on the distribution and magnitude of residual strains was also investigated. The results indicate that the residual strain in the cylinder bridge is tensile in both the axial and hoop components for both the as-cast and the heat-treated engine blocks. The residual strain in the hoop direction is bigger in magnitude than the residual strain in the axial direction. Heat treatment significantly relaxes the residual strain in the axial direction but only slightly relaxes the residual strain in the hoop direction.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Statistically generated weighted curve fit of residual functions for modal analysis of structures

A statistically generated weighting function for a second-order polynomial curve fit of residual functions has been developed. The residual flexibility test method, from which a residual function is generated, is a procedure for modal testing large structures in an external constraint-free environment to measure the effects of higher order modes and interface stiffness. This test method is applicable to structures with distinct degree-of-freedom interfaces to other system components. A theoretical residual function in the displacement/force domain has the characteristics of a relatively flat line in the lower frequencies and a slight upward curvature in the higher frequency range. In the test residual function, the above-mentioned characteristics can be seen in the data, but due to the present limitations in the modal parameter evaluation (natural frequencies and mode shapes) of test data, the residual function has regions of ragged data. A second order polynomial curve fit is required to obtain the residual flexibility term. A weighting function of the data is generated by examining the variances between neighboring data points. From a weighted second-order polynomial curve fit, an accurate residual flexibility value can be obtained. The residual flexibility value and free-free modes from testing are used to improve a mathematical model of the structure. The residual flexibility modal test method is applied to a straight beam with a trunnion appendage and a space shuttle payload pallet simulator.

Bookout, P. S.↗
NASA NTRS2017

Satellites May Underestimate Rice Residue and Associated Burning Emissions in Vietnam

In this study, we estimate rice residue, associated burning emissions, and compare results with existing emissions inventories employing a bottom-up approach. We first estimated field-level post-harvest rice residues, including separate fuel-loading factors for rice straw and rice stubble. Results suggested fuel-loading factors of 0.27 kg/sq m (+/-0.033), 0.61 kg/sq m (+/-0.076), and 0.88 kg/sq m (+/-0.083) for rice straw, stubble, and total post-harvest biomass, respectively. Using these factors, we quantified potential emissions from rice residue burning and compared our estimates with other studies. Our results suggest total rice residue burning emissions as 2.24 Gg PM2.5, 36.54 Gg CO and 567.79 Gg CO2 for Hanoi Province, which are significantly higher than earlier studies. We attribute our higher emission estimates to improved fuel-loading factors; moreover, we infer that some earlier studies relying on residue-to-product ratios could be underestimating rice residue emissions by more than a factor of 2.3 for Hanoi, Vietnam. Using the rice planted area data from the Vietnamese government, and combining our fuel-loading factors, we also estimated rice residue PM2.5 emissions for the entirety of Vietnam and compared these estimates with an existing all-sources emissions inventory, and the Global Fire Emissions Database (GFED). Results suggest 75.98 Gg of PM2.5 released from rice residue burning accounting for 12.8% of total emissions for Vietnam. The GFED database suggests 42.56 Gg PM2.5 from biomass burning with 5.62 Gg attributed to agricultural waste burning indicating satellite-based methods may be significantly underestimating emissions. Our results not only provide improved residue and emission estimates, but also highlight the need for emissions mitigation from rice residue burning.

Air pollution↗
DOE OSTI2022

A comprehensive study of non-adaptive and residual-based adaptive sampling for physics-informed neural networks

Physics-informed neural networks (PINNs) have shown to be effective tools for solving both forward and inverse problems of partial differential equations (PDEs). PINNs embed the PDEs into the loss of the neural network using automatic differentiation, and this PDE loss is evaluated at a set of scattered spatio-temporal points (called residual points). The location and distribution of these residual points are highly important to the performance of PINNs. However, in the existing studies on PINNs, only a few simple residual point sampling methods have mainly been used. Here, we present a comprehensive study of two categories of sampling for PINNs: non-adaptive uniform sampling and adaptive nonuniform sampling. We consider six uniform sampling methods, including (1) equispaced uniform grid, (2) uniformly random sampling, (3) Latin hypercube sampling, (4) Halton sequence, (5) Hammersley sequence, and (6) Sobol sequence. We also consider a resampling strategy for uniform sampling. To improve the sampling efficiency and the accuracy of PINNs, we propose two new residual-based adaptive sampling methods: residual-based adaptive distribution (RAD) and residual-based adaptive refinement with distribution (RAR-D), which dynamically improve the distribution of residual points based on the PDE residuals during training. Hence, we have considered a total of 10 different sampling methods, including six non-adaptive uniform sampling, uniform sampling with resampling, two proposed adaptive sampling, and an existing adaptive sampling. We extensively tested the performance of these sampling methods for four forward problems and two inverse problems in many setups. Our numerical results presented in this study are summarized from more than 6000 simulations of PINNs. Here, we show that the proposed adaptive sampling methods of RAD and RAR-D significantly improve the accuracy of PINNs with fewer residual points for both forward and inverse problems. Furthermore, the results obtained in this study can also be used as a practical guideline in choosing sampling methods.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

A recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness. Herein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness. Near-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness. Measured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter. The new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

42 ENGINEERING↗
DOE OSTI2023

Climate and air pollution impacts of generating biopower from forest management residues in California

California faces crisis conditions on its forested landscapes. A century of aggressive logging and fire suppression in combination with conditions exacerbated by climate change have created an ongoing ecological, economic, and public health emergency. Between commercial harvests on California’s working forestlands and the increasing number of acres the state treats each year for fire risk reduction and carbon sequestration, California forests generate millions of tons of woody residues annually—residues that are typically left or burned in the field. State policymakers have turned to biomass electricity generation as a key market for woody biomass in the hope that it can support sustainable forest management activities while also providing low-carbon renewable electricity. However, open questions surrounding the climate and air pollution performance of electricity generation from woody biomass have made it difficult to determine how best to manage the risks and opportunities posed by forest residues. The California Biomass Residue Emissions Characterization (C-BREC) model offers a spatially-explicit life cycle assessment framework to rigorously and transparently establish the climate and air pollution impacts of biopower from forest residues in California under current conditions. The C-BREC model characterizes the variable emissions from different biomass supply chains as well as the counterfactual emissions from prescribed burn, wildfire, and decay avoided by residue mobilization. We find that the life cycle ‘carbon footprint’ of biopower from woody residues generated by recent forest treatments in California ranges widely—from comparable with solar photovoltaic on the low end to comparable with natural gas on the high end. This variation stems largely from the heterogeneity in the fire and decay conditions these residues would encounter if left in the field, with utilization of residue that would otherwise have been burned in place offering the best climate and air quality performance. California’s energy and forest management policies should account for this variation to ensure desired climate benefits are achieved.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Dynamics of N 2 O in vicinity of plant residues: a microsensor approach

Plant residues decomposing within the soil matrix are known to serve as hotspots of N 2 O production. However, the lack of technical tools for microscale in-situ N 2 O measurements limits understanding of hotspot functioning. Our aim was to assess performance of microsensor technology for evaluating the temporal patterns of N 2 O production in immediate vicinity to decomposing plant residues. We incorporated intact switchgrass leaves and roots into soil matrix and monitored O 2 depletion and N 2 O production using electrochemical microsensors along with N 2 O emission from the soil. We also measured residue’s water absorption and b-glucosidase activity on the surface of the residue - the characteristics related to microenvironmental conditions and biological activity near the residue. N 2 O production in the vicinity of switchgrass residues began within 0–12 h after the wetting, reached peak at ~0.6 day and decreased by day 2. N 2 O was higher near leaf than near root residues due to greater leaf N contents and water absorption by the leaves. However, N 2 O production near the roots started sooner than near the leaves, in part due to high initial enzyme levels on root surfaces. Electrochemical microsensor is a useful tool for in-situ micro-scale N 2 O monitoring in immediate vicinity of soil incorporated plant residues. Monitoring provided valuable information on N 2 O production near leaves and roots, its temporal dynamic, and the factors affecting it. The N 2 O production from residues measured by microsensors was consistent with the N 2 O emission from the whole soil, demonstrating the validity of the microsensors for N 2 O hotspot studies.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Manganese effects on plant residue decomposition and carbon distribution in soil fractions depend on soil nitrogen availability

Recent studies have highlighted the critical role of manganese (Mn) in plant litter decomposition and soil organic carbon (C) cycling in forest ecosystems. Long term nitrogen (N) deposition and N fertilization can increase soil acidity and mobilize bioavailable Mn (Mn 2+ ) in soil. However, no studies have examined the interactive effect of N and Mn fertilization on litter decomposition and carbon distribution in agricultural soils, despite agroecosystems being subject to both N and Mn management. We hypothesized that increased soil N and Mn availability would accelerate plant residue decomposition and transfer of its C to mineral-associated organic matter (MAOM), and that the combined effect of Mn and N enrichment would be greater than the individual effect. Here, we conducted a laboratory incubation experiment by adding 13 C-labeled residue of perennial grass Glyceria striata (Lam.) to agricultural soils that had received 225 kg N ha –1 yr –1 for 27 years (N 1 ) and comparable soils that received no N (N 0 ). Before the experiment, these soils also received three levels of dissolved Mn 2+ , designated M 0 (no additional Mn), M 1 (50 mg kg –1 ), or M 2 (250 mg kg –1 ). We measured total CO 2 production as well as distribution of 13 C from the residue into CO 2 , particulate organic matter (POM), MAOM, and dissolved organic carbon (DOC) over a 1-year period. Manganese amendments significantly increased CO 2 production from residue decomposition in the N 1 soil, but no such effect was observed in the N 0 soil. Manganese also accelerated the loss of residue-derived C from POM and DOC, but increased its recovery in MAOM. However, the positive effect of added Mn in decomposition and recovery in MAOM in the presence of N fertilization occurred only during the initial 30-day decomposition period, where M 2 showed a 12% increase in cumulative CO 2 production from residue, 8% increase in POM loss, and 43% increase in recovery of residue C in MAOM compared to M 0 . For M 1 , only CO 2 emission from residue was significantly higher than Mo during this period. At 365 days M 2 showed 8% increase in CO 2 production, 1% increase in POM loss, and 16% increase in recovery of residue C in MAOM compared to M 0 , but none of these were statistically significant (p < 0.05). This study adds to the growing evidence that increasing Mn availability enhances plant litter decomposition. However, the occurrence and magnitude of Mn-induced stimulation of decomposition is context specific. Further investigation with greater temporal resolution, involving a multitude of litter and soil types and including microbial compositional and functional characterization, is recommended to fully elucidate the interactive role of Mn and N on C cycling.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

A deep dilated convolutional residual network for predicting interchain contacts of protein homodimers

Abstract Motivation Deep learning has revolutionized protein tertiary structure prediction recently. The cutting-edge deep learning methods such as AlphaFold can predict high-accuracy tertiary structures for most individual protein chains. However, the accuracy of predicting quaternary structures of protein complexes consisting of multiple chains is still relatively low due to lack of advanced deep learning methods in the field. Because interchain residue–residue contacts can be used as distance restraints to guide quaternary structure modeling, here we develop a deep dilated convolutional residual network method (DRCon) to predict interchain residue–residue contacts in homodimers from residue–residue co-evolutionary signals derived from multiple sequence alignments of monomers, intrachain residue–residue contacts of monomers extracted from true/predicted tertiary structures or predicted by deep learning, and other sequence and structural features. Results Tested on three homodimer test datasets (Homo_std dataset, DeepHomo dataset and CASP-CAPRI dataset), the precision of DRCon for top L/5 interchain contact predictions (L: length of monomer in a homodimer) is 43.46%, 47.10% and 33.50% respectively at 6 Å contact threshold, which is substantially better than DeepHomo and DNCON2_inter and similar to Glinter. Moreover, our experiments demonstrate that using predicted tertiary structure or intrachain contacts of monomers in the unbound state as input, DRCon still performs well, even though its accuracy is lower than using true tertiary structures in the bound state are used as input. Finally, our case study shows that good interchain contact predictions can be used to build high-accuracy quaternary structure models of homodimers. Availability and implementation The source code of DRCon is available at https://github.com/jianlin-cheng/DRCon. The datasets are available at https://zenodo.org/record/5998532#.YgF70vXMKsB. Supplementary information Supplementary data are available at Bioinformatics online.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1976

Lamination residual stresses in hybrid composites, part 1

An experimental investigation was conducted to study lamination residual stresses for various material and loading parameters. The effects of hybridization on residual stresses and residual properties after thermal cycling under load were determined in angle-ply graphite/Kevlar/epoxy and graphite/S-glass/epoxy laminates. Residual strains in the graphite plies are not appreciably affected by the type and number of hybridizing plies. Computed residual stresses at room temperature in the S-glass plies reach values up to seventy-five percent of the transverse strength of the material. Computed residual stresses in the graphite plies exceed the static strength by approximately ten percent. In the case of Kevlar plies, computed residual stresses far exceed the static strength indicating possible early failure of these plies. Static testing of the hybrids above indicates that failure is governed by the ultimate strain of the graphite plies. In thermally cycled hybrids, in general, residual moduli were somewhat lower and residual strengths were higher than initial values.

Daniel, I. M.↗
NASA NTRS2003

The effect of drying and size reduction pretreatments on recovery of inorganic crop nutrients from inedible wheat residues

Inorganic nutrients can be easily recovered from ALS crop residue solid wastes by aqueous leaching. However, oven drying and milling pretreatment of these residues has been frequently required to accommodate crop scientists and facility storage limitations. As part of a research study that will compare three different bioreactor technologies for processing these wastes, we realized that different drying and size-reduction pretreatments had been utilized for each technology. This paper compares the effects of residue pretreatment on recovery of nutrients by leaching. Pretreatments included three drying methods [fresh, oven-dried (70 degrees C overnight), and freeze-dried] and two size reduction methods [chopped (2 cm length) and milled (2 mm diameter)]. Determination of mass balances (dry weight and ash content of solids) before and after leaching indicated solubilization was least for fresh residues (23% dry weight loss and 50% for ash loss), and most for freeze-dried residues (41-47% dry weight loss and nearly 100% for ash loss). Mineral recovery of major elements (NO3, PO4, K, Ca, and Mg) in leachates was poorest for fresh residues. P and K recovery in leachates were best for oven-dried residues and Ca, Mg, and N recovery best for freeze-dried residues. The differences in recovery for N, P, and K in leachates were minimal between chopping and milling and slightly better for Ca and Mg from milled residues.

NASA Center KSC↗
DOE OSTI2024

Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Dimensional tolerances for high-speed-machined aluminum products continue to tighten due to the demand for automated assembly of complex monolithic parts in aerospace and other industries. Understanding the contribution of inherent residual stress in wrought Al 7050-T7451 plate, common in aircraft manufacture, to distortion of high-aspect-ratio machined parts is critical but remains problematic due to the alloy's low residual stress magnitude over large geometries. Prior investigations into residual stress effects on machined part distortion suffer inadequate characterizations of the wrought material stress field, either because of low fidelity due to “slitting” methods, confounding effects in machined-layer removal methods, or small sample size when using neutron diffraction (ND). In this work, inherent residual stress is measured via ND at 860 locations in a 90.5 mm thick Al 7050-T7451 plate having dimensions 399 mm in the rolling direction and 335 mm in the transverse direction. Unlike prior studies, the ND residual stress is reconstructed using an iterative algorithm to ensure fully compatible, equilibrated 3D field prior to examining its effect on distortion. Further, the findings from simulations and experiments show that inherent residual stress alone could distort a high-aspect-ratio part beyond aerospace industry requirements, that slitting measurements may not sufficiently characterize residual stress for predicted distortion, and that parts machined from different plate thickness locations could exhibit reversed distortion patterns. Thus, research into distortion prediction that considers machining should carefully characterize and reconstruct inherent residual stress so that the coupled machining effects are accurately modeled.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Residual stress and microstructure in IN718-René41 graded superalloy fabricated by laser blown directed energy deposition

Additively printed Ni-based superalloy with a compositionally graded transition from IN718 to René41 was fabricated by laser blown-powder directed energy deposition (DED/LB-M), with the goals of meeting location-specific temperature capability and reducing component cost for hot gas path turbine components. Residual stress distribution in thin wall specimens with three sets of DED build parameters in the as-built and stress-relieved states was measured by neutron diffraction. For calculating residual stress, the calculated d0 method was found to be more appropriate as stress-free reference than using the lattice spacing measured from the stress-relief heat treated specimens. Longer dwell time (lower interpass temperature), higher energy input, smaller layer thickness resulted in a higher magnitude of tensile residual stresses at edges and compressive residual stresses at center of the specimens. The residual stress results did not show a strong dependence on graded compositions, indicating that the residual stress build-up was more geometry and process dependent. Non-destructive neutron imaging based on the attenuation coefficient qualitatively visualized the compositional variation in the bulk and showed good agreement with quantitative Electron Probe Micro-Analysis (EPMA) measurement. Grain structure, texture, and residual plastic strain along the build direction were characterized by Electron Backscatter Diffraction (EBSD). Long columnar grains with (001) preferred grain orientation were dominant along the build direction. Compositional change did not show an obvious effect on the epitaxial growth of dendrites and the continuation of the columnar grains. Residual plastic strain was relatively low in the as-built specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessing microbial residues in soil as a potential carbon sink and moderator of carbon use efficiency

Abstract A longstanding assumption of glucose tracing experiments is that all glucose is microbially utilized during short incubations of ≤2 days to become microbial biomass or carbon dioxide. Carbon use efficiency (CUE) estimates have consequently ignored the formation of residues (non-living microbial products) although such materials could represent an important sink of glucose that is prone to stabilization as soil organic matter. We examined the dynamics of microbial residue formation from a short tracer experiment with frequent samplings over 72 h, and conducted a meta-analysis of previously published glucose tracing studies to assess the generality of these experimental results. Both our experiment and meta-analysis indicated 30–34% of amended glucose-C ( 13 C or 14 C) was in the form of residues within the first 6 h of substrate addition. We expand the conventional efficiency calculation to include residues in both the numerator and denominator of efficiency, thereby deriving a novel metric of the potential persistence of glucose-C in soil as living microbial biomass plus residues (‘carbon stabilization efficiency’). This new metric indicates nearly 40% of amended glucose-C persists in soil 180 days after amendment, the majority as non-biomass residues. Starting microbial biomass and clay content emerge as critical factors that positively promote such long term stabilization of labile C. Rapid residue production supports the conclusion that non-growth maintenance activity can illicit high demands for C in soil, perhaps equaling that directed towards growth, and that residues may have an underestimated role in the cycling and sequestration potential of C in soil.

Geyer, Kevin (ORCID:0000000252182745)↗
DOE OSTI2026

Comparative life cycle assessment of bioenergy in Japan from residual biomass-based wood pellets produced in the US Pacific Northwest

The US Pacific Northwest (PNW) faces an increase in wildfires due to forest overcrowding and climate change, posing significant environmental and public health risks. Traditional methods of managing surplus biomass, including prescribed burning, have increased air pollution and global warming. While in the PNW, residual woody biomass is being treated as waste, Japan’s growing demand for bio-based energy presents an opportunity to export value-added biomass as energy pellets. This study investigates whether producing wood pellets from the residual woody biomass from forest operations and sawmills for electricity generation in Japan is truly environmentally beneficial. Accordingly, we conducted a cradle-to-grave Life Cycle Assessment (LCA) to evaluate the environmental impact of residual pellets vs. coal for electricity generation. The assessment covered feedstock production, pellet processing, transportation, and combustion phases. Our findings indicate that replacing coal-based electricity in Japan with PNW residual pellet-based electricity can lower the Global Warming Potential (GWP) by about 90% for every unit of electricity displaced. Furthermore, the results show that repurposing the otherwise burnt harvest slash residues for pellet production would improve local air quality by reducing PM 2.5 and smog in the PNW. However, substituting coal with residual pellets marginally increased carcinogenic and ecotoxicity-related emissions. Based on these results, we conclude that substituting coal with residual wood pellets for electricity generation, particularly harvest-slash residual pellets, is environmentally beneficial across most impact categories, including the GWP. This research underscores how an export‑oriented pellet industry can help address the environmental challenges within the regional US wood products industry and global renewable energy supply.

Velappan, Hemalatha [Univ. of Washington, Seattle,↗
NASA NTRS1994

Measurement of the fluorescence of crop residues: A tool for controlling soil erosion

Management of crop residues, the portion of a crop left in the field after harvest, is an important conservation practice for minimizing soil erosion and for improving water quality. Quantification of crop residue cover is required to evaluate the effectiveness of conservation tillage practices. Methods are needed to quantify residue cover that are rapid, accurate, and objective. The fluorescence of crop residue was found to be a broadband phenomenon with emission maxima at 420 to 495 nm for excitations of 350 to 420 nm. Soils had low intensity broadband emissions over the 400 to 690 nm region for excitations of 300 to 600 nm. The range of relative fluorescence intensities for the crop residues was much greater than the fluorescence observed of the soils. As the crop residues decompose their blue fluorescence values approach the fluorescence of the soil. Fluorescence techniques are concluded to be less ambiguous and better suited for discriminating crop residues and soils than reflectance methods. If properly implemented, fluorescence techniques can be used to quantify, not only crop residue cover, but also photosynthetic efficiency in the field.

Daughtry, C. S. T.↗
NASA NTRS2007

Evaluation of Surface Residual Stresses in Friction Stir Welds Due to Laser and Shot Peening

The effects of laser, and shot peening on the residual stresses in Friction Stir Welds (FSW) has been investigated. The surface residual stresses were measured at five different locations across the weld in order to produce an adequate residual stress profile. The residual stresses before and after sectioning the coupon from the welded plate were also measured, and the effect of coupon size on the residual stress relaxation was determined and characterized. Measurements indicate that residual stresses were not uniform along the welded plate, and large variation in stress magnitude could be exhibited at various locations along the FSW plate. Sectioning resulted in significant residual stress relaxation in the longitudinal direction attributed to the large change in dimensions in this direction. Overall, Laser and shot peening resulted in a significant reduction in tensile residual stresses at the surface of the specimens.

Hatamleh, Omar↗
NASA NTRS2015

Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

Newman, John A.↗