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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 OSTI2026

Mechanical Behavior of Neutron Irradiated Refractory Multi-Principal Element Alloys Processed via Spark Plasma Sintering

The search for advanced materials capable of withstanding the extreme conditions of Generation IV reactors is a critical area in materials science research. These reactors operate under severe environments, including high temperatures, corrosion, stress, and irradiation damage. Consequently, there is a need for innovative alloy systems to ensure the reliability and longevity of proposed Generation IV reactor components. Refractory multi-principal-element alloys (RMPEA) have emerged as a promising candidate due to their exceptional properties. These alloys, characterized by their composition of multiple principal elements in near-equiatomic ratios, exhibit superior resistance to irradiation damage, reduced void swelling, enhanced microstructural stability, and minimal irradiation-induced hardening. While initial studies on RMPEAs have shown promising results, most research has been limited to thin films, nanocrystalline microstructures, and ion irradiation, which do not accurately represent the behavior of bulk materials. To address this gap, our research focused on the neutron irradiation of bulk RMPEAs. We aim to conduct comprehensive post-irradiation examinations (PIE) of RMPEAs irradiated at the Advanced Test Reactor at Idaho National Laboratory. The RMPEAs were synthesized using spark plasma sintering (SPS) with mechanically alloyed metallurgical powder. The RMPEA specimens are a MoNbTi alloy system with additions of -Zr, and -ZrV. Furthermore, PIE consisted of mechanical testing and advanced materials characterization. The mechanical testing consisted of sub-sized tensile testing, micro- and nano- indentation. Microstructural characterization included scanning electron microscopy and transmission electron microscopy. Mechanical testing coupled with advanced microscopy techniques provides insight into phase morphology and its effects on the mechanical properties of the RMPEA specimens. The results indicate that both pristine and irradiated RMPEA specimens exhibited brittle behavior during tensile testing, which can be attributed to their heterogeneous microstructure. The SPS manufacturing process did not include any post treatment, which resulted in a heterogeneous microstructure. Energy-dispersive X-ray spectroscopy revealed the presence of intermetallic such as laves phases within the microstructure. Specifically, Ti-rich precipitates were observed in the MoNbTi specimen, while Mo-rich precipitates were found in the MoNbTiZrV specimen. Nano-hardness testing of pristine samples showed that the laves phases exhibited higher hardness values compared to the matrix phase, suggesting that precipitate hardening is likely the dominant hardening mechanism in these specimens. The results from this work will be used to build a finite element model to predict mechanical behavior of future MPEA compositions. Thus, enabling for a streamlined approach to developing novel MPEAs for the nuclear industry.

36 - MATERIALS SCIENCE↗
NASA NTRS1984

A simple application of the Bailey-Orowan creep model to Fe-39.8 at. pct Al and gamma/gamma prime - alpha

The results of a study to determine the recovery rates and work-hardening coefficients for creep from constant cross-head speed compressive tests are presented. Stressing and straining rates are computed from measured time-load curves obtained from compression testing between 1200 and 1400 K of several B2 crystal structure Fe-39.8 Al intermetallic materials and the directionally solidified eutectic alloy gamma/gamma prime alpha. These quantities are then fitted to the universal form of the Bailey-Orowan equation for creep. The recovery rates were found to be functions of nominal strain rate, stress, and temperature, while the hardening coefficients were dependent only on temperature. While the work-hardening coefficient for gamma/gamma prime - alpha was about 0.05 of the elastic modulus, the work-hardening coefficients for Fe-39.8 at. pct Al were less than 0.002 of the modulus.

Whittenberger, J. D.↗
DOE OSTI2023

Unraveling kinking: A plasticity enhancing failure mode in high strength nano metallic laminates

Kinking is an important and plasticity-enhancing deformation/failure mode in numerous mechanically anisotropic materials including high-strength nano metallic laminates (NMLs). However, our current limited understanding of the mechanics of kinking and its dependence on microstructural attributes is insufficient for thoroughly comprehending and eventually being able to control failure behaviors of materials. In this study, we investigate kinking dependencies on microstructural attributes in NMLs via in situ micropillar compression, multiscale microstructure characterization, dislocation dynamic simulations, and crystal plasticity modeling. Additionally, by examining several NML systems (Cu/Fe, Ag/Fe, Al-4Mg/Fe), we demonstrate that the development of internal stresses during loading activates local layer-parallel glide triggering kinking in NMLs. Furthermore, this work reveals the effect of key microstructural features including layer thickness, layer waviness, interface barrier strength, and work hardening capacity on kink band formation in NMLs. More broadly, our efforts represent a generically applicable approach for probing large-strain deformation behavior of complex materials via synergetic modeling and experimental efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Beam Hardening Artifact Reduction in X-Ray CT Reconstruction of 3D Printed Metal Parts Leveraging Deep Learning and CAD Models

Nondestructive evaluation (NDE) of additively manufactured (AM) parts is important for understanding the impacts of various process parameters and qualifying the built part. X-ray computed tomography (XCT) has played a critical role in rapid NDE and characterization of AM parts. However, XCT of metal AM parts can be challenging because of artifacts produced by standard reconstruction algorithms as a result of a confounding effect called “beam hardening.” Beam hardening artifacts complicate the analysis of XCT images and adversely impact the process of detecting defects, such as pores and cracks, which is key to ensuring the quality of the parts being printed. In this work, we propose a novel framework based on using available computer-aided design (CAD) models for parts to be manufactured, accurate XCT simulations, and a deep-neural network to produce high-quality XCT reconstructions from data that are affected by noise and beam hardening. Using extensive experiments with simulated data sets, we demonstrate that our method can significantly improve the reconstruction quality, thereby enabling better detection of defects compared with the state of the art. We also present promising preliminary results of applying the deep networks trained using CAD models to experimental data obtained from XCT of an AM jet-engine turbine blade.

Ziabari, Amir↗
NASA NTRS1991

Micromechanical analysis of filamentary metal matrix composites under longitudinal loading

A two-material composite cylinder model (CCM) was considered for the study of the mechanical behavior at different temperatures of a fiber-reinforced silicon carbide/aluminum (SiC/Al) composite. An elastoplastic analysis of the model was performed in which the fiber was assumed to be linear elastic and the matrix elastoplastic with work-hardening. The analysis was based on the deformation theory of plasticity in conjunction with the von-Mises yield criterion. Experimental stress-strain curves of an SiC/Al composite were obtained at 24 and 288 C (75 and 550 F). The complete three-dimensional stress distribution in the composite using the CCM was determined. It was found that, in addition to longitudinal stresses, transverse stresses in both the fiber and the matrix were developed as a result of the different Poisson's ratios of the two materials. The transverse stresses, although much smaller than the longitudinal stresses, contributed to the plastic deformation of the matrix. The experimental stress-strain curves were favorably compared with the theoretical predictions.

Gdoutos, Emmanuel E.↗
NASA NTRS1986

Constitutive modeling for isotropic materials

The objective of the program is to evaluate and develop existing constitutive models for use in finite-element structural analysis of turbine engine hot section components. The class of constitutive equation studied is considered unified in that all inelastic deformation including plasticity, creep, and stress relaxation are treated in a single term rather than a classical separation of plasticity (time independent) and creep (time dependent) behavior. The unified theories employed also do not utilize the classical yield surface or plastic potential concept. The models are constructed from an appropriate flow law, a scalar kinetic relation between strain rate, temperature and stress, and evolutionary equations for internal variables describing strain or work hardening, both isotropic and directional (kinematic). This and other studies have shown that the unified approach is particularly suited for determining the cyclic behavior of superalloy type blade and vane materials and is entirely compatible with three-dimensional inelastic finite-element formulations. The behavior was examined of a second nickel-base alloy, MAR-M247, and compared it with the Bodner-Partom model, further examined procedures for determining the material-specific constants in the models, and exercised the MARC code for a turbine blade under simulated flight spectrum loading. Results are summarized.

Lindholm, Ulric S.↗
DOE OSTI2022

On the Prediction of Uniaxial Tensile Behavior Beyond the Yield Point of Wrought and Additively Manufactured Ti-6Al-4V

In this paper, phenomenological relationships are presented that permit the prediction of the plastic regime of stress–strain curves using a limited number of parameters. These relationships were obtained from both conventional (wrought + β annealed) and additively manufactured (i.e., “3D printed”) Ti-6Al-4V. Three different methods of additive manufacturing have been exploited to produce the materials, including large-volume electron beam additive manufacturing, large-volume laser hot wire additive manufacturing, and small-volume selective laser melting. The general fundamental expressions are independent not only of the additive manufacturing process, but also of a wide variety of post-deposition heat treatments, however the coefficients are specific to material states. Thus, this work demonstrates that it is possible to predict not only the ultimate tensile strength, but also the full true stress, true strain curves, if certain parameters of the material are known. In general, the prediction of ultimate tensile strength are within 5% of the experimentally measured values across all additive manufacturing variants and subsequent heat treatments. The absolute values of ultimate tensile strength range from ~ 910 MPa to ~ 1170 MPa for the single alloy Ti-6Al-4V. Data representing 113 explicit samples are included in this work.

36 MATERIALS SCIENCE↗
NASA NTRS2024

Fault Diagnosis of Power Components with Reliability Assessment in Extraterrestrial Microgrids

This research investigates the possible failures caused by aging and other environmental and external factors that could significantly impact the performance of extraterrestrial power systems. Additionally, it presents a reliability assessment model for the space microgrid based on fault tree analysis (FTA). The reliability assessment model developed in this paper represents a tool that can be used by engineers to harden the system design for operational and economic benefits. To improve the reliability of the system, this work provides a broad review of the different fault detection and diagnosis (FDD) algorithms used for power microgrids and space applications. Using data sets from the Habitat Simulator developed through the NASA-funded Resilient Extraterrestrial Habitat Institute, this paper compares the applicability and accuracy of the different FDD methods. The primary FDD approach proposed and assessed in this work is based on the Markov reliability model. It predicts and detects future faults in the space microgrids by using past data samples and categorizing them into different classes. Data-driven-based models such as artificial neural networks are also investigated, tested, and evaluated using simulation data sets. According to the simulation results and the broad FDD algorithm comparison, this study provides the crew or maintenance engineers with a clear methodology to detect and localize power system failures.

Leila Chebbo↗
NASA NTRS1993

Elastic-plastic finite element analyses of an unidirectional, 9 vol percent tungsten fiber reinforced copper matrix composite

Micromechanical modeling via elastic-plastic finite element analyses were performed to investigate the effects that the residual stresses and the degree of matrix work hardening (i.e., cold-worked, annealed) have upon the behavior of a 9 vol percent, unidirectional W/Cu composite, undergoing tensile loading. The inclusion of the residual stress-containing state as well as the simulated matrix material conditions proved to be significant since the Cu matrix material exhibited plastic deformation, which affected the subsequent tensile response of the composite system. The stresses generated during cooldown to room temperature from the manufacturing temperature were more of a factor on the annealed-matrix composite, since they induced the softened matrix to plastically flow. This event limited the total load-carrying capacity of this matrix-dominated, ductile-ductile type material system. Plastic deformation of the hardened-matrix composite during the thermal cooldown stage was not considerable, therefore, the composite was able to sustain a higher stress before showing any appreciable matrix plasticity. The predicted room temperature, stress-strain response, and deformation stages under both material conditions represented upper and lower bounds characteristic of the composite's tensile behavior. The initial deformation stage for the hardened material condition showed negligible matrix plastic deformation while for the annealed state, its initial deformation stage showed extensive matrix plasticity. Both material conditions exhibited a final deformation stage where the fiber and matrix were straining plastically. The predicted stress-strain results were compared to the experimental, room temperature, tensile stress-strain curve generated from this particular composite system. The analyses indicated that the actual thermal-mechanical state of the composite's Cu matrix, represented by the experimental data, followed the annealed material condition.

Sanfeliz, Jose G.↗
DOE OSTI2026

Dynamic crushing of metal lattice metamaterials: Shock mode diagrams and transition to topology-independent compaction regime

Additively manufactured lattice metamaterials offer design versatility in strength and energy absorption and provide an additional degree of freedom through the selection of the lattice topology. Under quasistatic loading, the unit cell structure can strongly affect the stiffness, yield, and post-yield behavior, but whether and to what degree the effect of lattice topology persists into dynamic loading scenarios, up to the compaction shock regime, has not been established. LLNL’ s ALE3D hydrocode was used to perform a computational investigation of dynamic loading in multiple lattice types, including the gyroid, octet, Schwarz D, and rhombic dodecahedron, under impact velocities from 0.25 to 2.25 km/s. Shock Hugoniots for each lattice topology are generated and compared, suggesting that above a critical velocity, distinctions between architectures may not persevere and compacted lattices behave similarly. Here, to investigate the transition between topology-dependent quasistatic compression and the topology-independent regime above the critical velocity, a one-dimensional elastic-linear hardening plasticity-densified solid (E-LHP-DS) shock model for lattice materials was developed that relies upon confined compression to link the quasistatic and shock mechanics. Unlike similar works, the model does not assume rigid behavior prior to yield or locking behavior at densification, allowing a richer exploration of lattice mechanics. With only six parameters, the analytical model simultaneously fit quasistatic confined compression simulations for relative densities 0.1 $≤ \bar{ρ} ≤$ 0.9 and predicted dynamic compaction behavior to traverse several distinct shock modes, each defined by a critical impact speed (equivalently, critical stresses). Comparing the numerical results to the one-dimensional E-LHP-DS shock model predictions suggests that the topology-independence under strong shocks is linked to the onset of densification, which can be predicted based on quasistatic confined compression results.

Cellular material↗
DOE OSTI2020

Mitigating Cascading Outages in Severe Weather Using Simulation-Based Optimization

Severe weather events can trigger cascading power outages and lead to significant losses. In this work, we investigate cascading outage mitigation under severe weather conditions. Given day-ahead weather forecasts and component failure models, we aim to identify a set of power lines that can be hardened to minimize the expected impact of potential cascading outages. Since the expected load shedding cannot be expressed as an explicit function of line hardening decisions and system states, we developed a cascading outage simulator to estimate the expected value of load shedding under various initial weather-related disruption scenarios generated using a weather forecast. To avoid massive enumeration of all possible combinations of line hardening decisions and reduce the simulation efforts, we employed an efficient simulation-based optimization approach that quickly identifies the (near) optimal line hardening decisions in the presence of both large simulation noises due to the highly variable initial disturbances and system states, and significant randomness in the subsequent cascades. Furthermore, the algorithm is also able to utilize parallel computing to dramatically reduce computation time to support decision making in preparation for severe weather conditions. We performed a case study on the Northeast Power Coordinating Council (NPCC) 140-bus system model to demonstrate that our approach can significantly improve power grid resilience to adverse weather events.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1988

A theory of viscoplasticity accounting for internal damage

A constitutive theory for use in structural and durability analyses of high temperature isotropic alloys is presented. Constitutive equations based upon a potential function are determined from conditions of stability and physical considerations. The theory is self-consistent; terms are not added in an ad hoc manner. It extends a proven viscoplastic model by introducing the Kachanov-Rabotnov concept of net stress. Material degradation and inelastic deformation are unified; they evolve simultaneously and interactively. Both isotropic hardening and material degradation evolve with dissipated work which is the sum of inelastic work and internal work. Internal work is a continuum measure of the stored free energy resulting from inelastic deformation.

Freed, A. D.↗
DOE OSTI2021

OC6 Phase II: Integration and verification of a new soil–structure interaction model for offshore wind design

Abstract This paper provides a summary of the work done within the OC6 Phase II project, which was focused on the implementation and verification of an advanced soil–structure interaction model for offshore wind system design and analysis. The soil–structure interaction model comes from the REDWIN project and uses an elastoplastic, macroelement model with kinematic hardening, which captures the stiffness and damping characteristics of offshore wind foundations more accurately than more traditional and simplified soil–structure interaction modeling approaches. Participants in the OC6 project integrated this macroelement capability to coupled aero‐hydro‐servo‐elastic offshore wind turbine modeling tools and verified the implementation by comparing simulation results across the modeling tools for an example monopile design. The simulation results were also compared to more traditional soil–structure interaction modeling approaches like apparent fixity, coupled springs, and distributed springs models. The macroelement approach resulted in smaller overall loading in the system due to both shifts in the system frequencies and increased energy dissipation. No validation work was performed, but the macroelement approach has shown increased accuracy within the REDWIN project, resulting in decreased uncertainty in the design. For the monopile design investigated here, that implies a less conservative and thus more cost‐effective offshore wind design.

17 WIND ENERGY↗
NASA NTRS2009

Understanding how molecular hydrogen impacts the total dose and dose rate response of linear bipolar circuits

Recent Enhanced Low Dose Rate Sensitivity (ELDRS) investigations carried out by RLP Research, Arizona State University (ASU) and Jet Propulsion Laboratory (JPL) have shown significant differences in the degradation of bipolar micro-circuits with total dose in the presence of molecular hydrogen (H2) in packages. This has a significant impact on radiation hardness assurance and opens up opportunities to improve device performance. The general objectives of this program are to: 1. Determine the extent to which hydrogen contamination affects the total dose and dose rate response of linear bipolar circuits; 2. Develop a model that will enable the prediction of high dose rate (HDR) and low dose rate (LDR) response asymptotes and transition dose rates as a function of total dose, temperature, pressurized hydrogen, defect precursors, and other process dependent variables; 3. Explore the possibility of an accelerated hardness assurance method and possible hardening approaches; and 4. Extend the work to other technologies that have total dose response affected by hydrogen contamination.In this document, we xperimentally demonstrate with test transistors and circuits that hydrogen is correlated with ELDRS in bipolar linear circuits. We show that the amount of hydrogen determines: 1) the total dose response versus dose rate and 2) the transition dose rates between the high and low dose rate responses. The experimental results are supported with a steady state drift/diffusion analytical model as well as modeling calculations using COMSOL Multiphysics.

Pease, Ron↗
DOE OSTI2024

Simultaneous Optimization of Crystal Plasticity Hardening Parameters

Crystal plasticity models relate macroscopic deformation behavior to the evolution of slip systems strength, but their parameterization is often non-unique, with multiple parameter sets being able to describe the same macroscopic behavior. To address this issue, the present work adopts a Bayesian optimization framework for the parameterization of face-centered cubic plasticity models while simultaneously considering multiple experimental datasets from the literature. For single crystal Cu, parameter optimization was guided by the tensile stress–strain curves along several crystallographic orientations, with an adequate fit being found for five orientations at once. While additional parameters allowed for the consideration of more physical mechanisms, like different slip system interaction strengths or misorientations inherent to the experimental data, the extra dimensionality was found to limit the efficiency of the global minimization procedure. For polycrystalline Ni, multiple grain sizes were considered together in a representative polycrystalline model, with the optimization able to reconcile the model with the data for three grain sizes at once. As meaningful interpretation of parameters relies on the uniqueness of their values, incorporating multiple datasets into this discerning parameterization procedure enables more robust prediction and application of crystal plasticity models.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Nondestructive ultrasonic characterization of two-phase materials

The development of ultrasonic methods for the nondestructive characterization of mechanical properties of two phase engineering materials are described. The primary goal was to establish relationships between the nonlinearity parameter and the percentage of solid solution phase in two phase systems such as heat treatable aluminum alloys. The acoustoelastic constant was also measured on these alloys. A major advantage of the nonlinearity parameter over that of the acoustoelastic constant is that it may be determined without the application of stress on the material, which makes the method more applicable to inservice nondestructive characterization. The results obtained on the heat treatable 7075 and the work hardenable 5086 and 5456 aluminum alloys show that both the acoustoelastic constant and the acoustic nonlinearity parameter change considerable with the volume fraction of second phase precipitates in these aluminum alloys. A mathematical model was also developed to relate the effective acoustic nonlinearity parameter to volume fraction of second phase precipitates in an alloy. The equation is approximated to within experimental error by a linear expression for volume fractions up to approx. 10%.

Salama, Kamel↗
NASA NTRS1988

The effect of temperature on the deformation structure of single crystal nickel based superalloys

Results for the temperature dependence of the yield and flow stress were obtained for the superalloys PWA 1480 and CMSX-2. An extended Copley-Kear (1967) model is used to predict flow stresses from the dislocation densities measured at different strains and temperatures. Differences found between the two superalloys include the development of their dislocation structure, their ductility, and their work hardening characteristics.

Dollar, M.↗
NASA NTRS1989

Parallel processors and nonlinear structural dynamics algorithms and software

A nonlinear structural dynamics finite element program was developed to run on a shared memory multiprocessor with pipeline processors. The program, WHAMS, was used as a framework for this work. The program employs explicit time integration and has the capability to handle both the nonlinear material behavior and large displacement response of 3-D structures. The elasto-plastic material model uses an isotropic strain hardening law which is input as a piecewise linear function. Geometric nonlinearities are handled by a corotational formulation in which a coordinate system is embedded at the integration point of each element. Currently, the program has an element library consisting of a beam element based on Euler-Bernoulli theory and trianglar and quadrilateral plate element based on Mindlin theory.

Belytschko, Ted↗