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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

Peel testing metalized films

Flimsy ultrathin sheets are mounted on glass for peel-strength measurements. Technique makes it easier to perform peel tests on metalized plastic films. Technique was developed for determining peel strength of thin (1,000 A) layers of aluminum on Kapton film. Previously, material has been difficult to test because it is flimsy and tends to curl up and blow away at slightest disturbance. Procedure can be used to measure effects on metalization bond strength of handling, humidity, sunlight, and heat.

Bivins, L.↗

Design and Analysis of a Stiffened Composite Structure Repair Concept

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. Since the repair concept is a bolted repair using metal components, it can easily be applied in the operational environment. Initial analyses are aimed at validating the finite element modeling approach by comparing with available test data. Once confidence in the analysis approach is established several repair configurations are explored and the most efficient one presented. Repairs involving damage to the top of the stiffener alone are considered in addition to repairs involving a damaged stiffener, flange and underlying skin. High fidelity finite element modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic metallic material properties and geometrically nonlinear analysis are utilized in the effort. The results of the analysis are presented and factors influencing the design are assessed and discussed.

Przekop, Adam↗

Viscoplastic Model Development to Account for Strength Differential: Application to Aged Inconel 718 at Elevated Temperature

The magnitude of yield and flow stresses in aged Inconel 718 are observed to be different in tension and compression. This phenomenon, called the Strength differential (SD), contradicts the metal plasticity axiom that the second deviatoric stress invariant alone is sufficient for representing yield and flow. Apparently, at least one of the other two stress invariants is also significant. A unified viscoplastic model was developed that is able to account for the SD effect in aged Inconel 718. Building this model involved both theory and experiments. First, a general threshold function was proposed that depends on all three stress invariants and then the flow and evolution laws were developed using a potential-based thermodynamic framework. Judiciously chosen shear and axial tests were conducted to characterize the material. Shear tests involved monotonic loading, relaxation, and creep tests with different loading rates and load levels. The axial tests were tension and compression tests that resulted in sufficiently large inelastic strains. All tests were performed at 650 C. The viscoplastic material parameters were determined by optimizing the fit to the shear tests, during which the first and the third stress invariants remained zero. The threshold surface parameters were then fit to the tension and compression test data. An experimental procedure was established to quantify the effect of each stress invariant on inelastic deformation. This requires conducting tests with nonproportional three-dimensional load paths. Validation of the model was done using biaxial tests on tubular specimens of aged Inconel 718 using proportional and nonproportional axial-torsion loading. These biaxial tests also helped to determine the most appropriate form of the threshold function; that is, how to combine the stress invariants. Of the set of trial threshold functions, the ones that incorporated the third stress invariant give the best predictions. However, inclusion of the first stress invariant does not significantly improve the model predictions. The model shows excellent predictive capability for nonproportional load paths. Additionally, it reduces to the well-known models of Mises Drucker and Drucker-Prager. The requisite experiments involve reasonably simple load paths in the axial-shear stress plane and hence can be performed on a variety of different materials: be they metallic, geological. polymeric, ceramic or granular. The general form of the threshold function allows representation of inelastic deformation in a range of materials.

Iyer, Saiganesh↗

Discrete stochastic model of point defect-dislocation interaction for simulating dislocation climb

Dislocation climb is an important high temperature process in metals plasticity, responsible for the phenomena such as creep, swelling, or hardening. Climb is defined by the ability of dislocations to leave their original glide plane by interacting with point defects. As such, dislocation climb is controlled by point defect diffusion/absorption/emission, all of which involve thermal activation. The existing thermodynamically consistent models for climb are generally formulated in a continuum framework, through the definition of effective defect fluxes and climb propensities in response to thermodynamic driving forces. However, the point-wise discrete nature of vacancies (and/or self-interstitials) confers a highly discrete nature to the climb dynamics, which is also strongly affected by elastic forces. The combination of discreteness, thermal activation, and elasticity makes this process too challenging for direct atomistic methods such as molecular dynamics. Here we develop a kinetic Monte Carlo model that captures vacancy generation and transport kinetics acting in conjuction with the evolving elastic fields provided by discrete dislocation dynamics simulations. The two models are coupled via the applied stresses and stress gradients generated by dislocation structures at vacancy locations. Our simulations reveal two surprising results. First that climb is dominated by vacancy emission even when the background vacancy concentration is much higher than the equilibrium one. And, second, that climb velocities might be much faster than otherwise believed when one uses the classical theories of climb. These effects are due to the locality of vacancy-dislocation processes, which are not captured in classical treatments that assume smooth vacancy fluxes and homogeneous concentrations. We apply the method to study elementary climb processes in body-centered cubic iron and furnish climb mobility functions to be used in parametric dislocation dynamics and/or crystal plasticity simulations. Here, we apply the technique to study non-conservative plastic bypass of spherical precipitates by edge dislocations and point out the differences between our discrete approach and existing continuum formulations.

36 MATERIALS SCIENCE↗

Large rotations of the grain-scale stress tensor during yielding set the stage for failure

The stress-state within individual grains in a polycrystal determine the fate of the aggregate including mechanical failure. By tracking the evolution of the stress tensor throughout the elastoplastic transition, large rotations of the stress-state, which have long been theorized to occur, are observed experimentally for the first time. These stress rotations (~15°) are more than an order of magnitude larger than the concomitant crystallographic lattice reorientations (~0.9°) well-known to occur during metal plasticity. Furthermore, these rotations are accompanied by a decrease in stress triaxiality within certain grains, promote strain softening, and set the stage for failure at an early stage of deformation. Finally, these results provide a completely new perspective through which to contemplate the question of “hot-spots” responsible for failure of high-performance structural materials.

36 MATERIALS SCIENCE↗

Techno-economics of hydrocarbon fuel production and recyclables recovery from landfill-destined municipal solid waste: AI-enhanced materials recovery facility design

Sustainable aviation fuels (SAF) production from cellulosic paper fractions of municipal solid waste (MSW) destined for landfills has strong potential to advance environmental, social, and economic sustainability across the aviation and waste sectors. This study proposes an artificial intelligence-enabled material recovery facility (AI-MRF) design to efficiently characterize, separate, process, and convert recovered paper waste from MSW into intermediate chemicals and SAF. The AI-MRF, designed to process 233,091 metric tons of MSW annually, integrates smart manufacturing technologies including AI, visual and hyperspectral imaging, multi-sensor data, and traditional sorting systems. Well-characterized and sorted cellulosic paper waste was utilized for chemical and fuel production scenarios, while clean plastics, metals, and glass were considered for recycling. Conversion of paper waste into intermediate sugars achieved a net present value (NPV) of up to $\$67$ million. For sugar-to-SAF production scenarios, the minimum fuel selling price (MFSP) was calculated at $\$6.11$ per gasoline gallon equivalent (GGE) when excluding recyclable revenue, and $\$4.03$ per GGE when halving recyclable revenue. The MFSP was further reduced to $\$1.96$ per GGE when accounting for SAF sales and recyclables. Nationally, this approach could yield about 2 billion GGE of hydrocarbon fuel annually from available MSW in the United States.

09 BIOMASS FUELS↗

Cross-scale covariance for material property prediction

A simulation can stand its ground against an experiment only if its prediction uncertainty is known. The unknown accuracy of interatomic potentials (IPs) is a major source of prediction uncertainty, severely limiting the use of large-scale classical atomistic simulations in a wide range of scientific and engineering applications. Here we explore covariance between predictions of metal plasticity, from 178 large-scale (~10 8 atoms) molecular dynamics (MD) simulations, and a variety of indicator properties computed at small-scales (≤10 2 atoms). All simulations use the same 178 IPs. In a manner similar to statistical studies in public health, we analyze correlations of strength with indicators, identify the best predictor properties, and build a cross-scale “strength-on-predictors” regression model. This model is then used to estimate regression error over the statistical pool of IPs. Small-scale predictors found to be highly covariant with strength are computed using expensive quantum-accurate calculations and used to predict flow strength, within the statistical error bounds established in our study.

36 MATERIALS SCIENCE↗

Requirements Documents for the Large Mechanical Parts Precision Cleaner (LMPPC) in the Optics Assembly Building (OAB)

The National Ignition Facility (NIF) is the world's largest energetic laser whose missions include sresearch in inertial confinement fusion, experiments for the Stockpile Stewardship, and other high fluence laser research. Due to the high fluence of lasers, extreme environmental conditions, and radiation presence, all mechanical parts (metal, plastic, etc.) installed on NIF must be precision cleaned. Precision cleaned parts are also required in supporting facilities like the Optics Processing Facility (OPF). Small debris inside the laser beams or on optics can cause optic damage, interfere with diagnostics, and interfere with experiments.

42 ENGINEERING↗

Conversion of Domestic US Coal into Exceedingly High-Quality Graphene

The Recipient will study how flash Joule heating (FJH) from anthracite coal can afford high value graphene in gram scales in less than 1 second per conversion step. The graphene is termed flash graphene (FG). The process uses no furnace and no solvent or reactive gases, and the yields from anthracite coal are 85-95% with a purity >99%. The scaled electrical energy cost is projected at $100 per metric ton. FG can be among the lowest defect graphene ever reported (2D/G = 17:1) and turbostratic by powder X-ray diffraction (XRD) analysis, meaning that is has little order between the graphene layers, thereby facilitating its dispersion in composites. FG might provide the long-sought method to make graphene in bulk with industrially acceptable economics: inexpensive coal, furnace-free, solvent-free and chemical-free processing, and low-energy input to render it suitable for bulk plastic, metal and even concrete composites.

01 COAL, LIGNITE, AND PEAT↗

Environmental Persistence of Monkeypox Virus on Surfaces in Household of Person with Travel-Associated Infection, Dallas, Texas, USA, 2021

In July 2021, we conducted environmental sampling at the residence of a person in Dallas, Texas, USA, who had travel-associated human West African monkeypox virus (MPXV-WA). Targeted environmental swab sampling was conducted 15 days after the person who had monkeypox left the household. Results indicate extensive MPXV-WA DNA contamination, and viable virus from 7 samples was successfully isolated in cell culture. There was no statistical difference (p = 0.94) between MPXV-WA PCR positivity of porous (9/10, 90%) vs. nonporous (19/21, 90.5%) surfaces, but there was a significant difference (p<0.01) between viable virus detected in cultures of porous (6/10, 60%) vs. nonporous (1/21, 5%) surfaces. These findings indicate that porous surfaces (e.g., bedding, clothing) may pose more of a MPXV exposure risk than nonporous surfaces (e.g., metal, plastic). Viable MPXV was detected on household surfaces after at least 15 days. However, low titers (<102 PFU) indicate a limited potential for indirect transmission.

60 APPLIED LIFE SCIENCES↗

Better Seals for Vacuum Bags

Roller tool spreads even layer of adhesive. Tool easily constructed from metal, plastic, or wood. Sewing-thread spool serves as roller, nail as axle, and jigsawed block of wood as handle. Tool rolled and pressed against plastic film to assure even layer of adhesive around periphery.

Penn, B.↗

Unified viscoplastic constitutive equations and their applications

Unified constitutive equations for time- and temperature-dependent metallic plastic deformation have been applied in FEM simulations of forming processes; increasingly powerful computational tools and physical models are being used to numerically model complex engineering problems. Once confidence has been gained through adequate verification, these numerical models will increasingly replace experimental models. Attention is presently given to the contributions made by physical metallurgy, continuum mechanics, and computational mechanics.

Lindholm, U. S.↗

Mold bolt and means for achieving close tolerances between bolts and bolt holes

In the space shuttle, a cargo bay storage rack was required which was to be manufactured from a metal-plastic composite and bolted to a cargo structure. Following completion, utilization of the rack was disallowed due to tolerances, that is, the size differences between the outside bolt diameter and the inside hole diameter. In addition to the space shuttle problem there are other close tolerance requirements for bolts. Such environments often benefit from close tolerance bolting. Frequently such fabrication is not cost effective. Consequently there is a need for means of achieving close tolerances between bolts and bolt holes. Such means are provided. After compressing the elements together a strong rigid plastic, ceramic, or ceramic plastic fluid is forced into a channel extending through the bolt.

Johnston, David L.↗