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NASA NTRS1975

Fundamental analysis of the failure of polymer-based fiber reinforced composites

A mathematical model predicting the strength of unidirectional fiber reinforced composites containing known flaws and with linear elastic-brittle material behavior was developed. The approach was to imbed a local heterogeneous region surrounding the crack tip into an anisotropic elastic continuum. This (1) permits an explicit analysis of the micromechanical processes involved in the fracture, and (2) remains simple enough to be useful in practical computations. Computations for arbitrary flaw size and orientation under arbitrary applied loads were performed. The mechanical properties were those of graphite epoxy. With the rupture properties arbitrarily varied to test the capabilities of the model to reflect real fracture modes, it was shown that fiber breakage, matrix crazing, crack bridging, matrix-fiber debonding, and axial splitting can all occur during a period of (gradually) increasing load prior to catastrophic failure. The calculations also reveal the sequential nature of the stable crack growth process proceding fracture.

Kanninen, M. F.↗

DOE OSTI2022

A New Model for Simulating the Imbibition of a Wetting-Phase Fluid in a Matrix-Fracture Dual Connectivity System

The imbibition experiment is an effective approach for measuring petrophysical properties of porous media, with many such experiments performed over the past decade. Quite some empirical, analytical, and numerical models have been developed to simulate spontaneous imbibition of the wetting phase fluid into porous media, but limitations still exist. In previous studies, the imbibition process has been considered to give a piston-like displacement or the porous medium modeled as multiply-sized pores linked with bonds; both approaches fail to yield comprehensive results due to their neglect of the presence of irregular fractures or nonuniform flow paths through the matrix. By building a numerical model for simulating laboratory-scale experimental data, we performed imbibition tests on several fractured Barnett Shale samples having fractures either parallel ( P ) or transverse ( T ) to the bedding plane and used MATLAB to build a new numerical model by combining the imbibition process in fractures and the matrix using concepts from percolation theory. The experimental data show that the rocks with P -direction fractures have a more steady increase of imbibition rates than the case of T -direction one. As the shale matrix with low pore connectivity hampers the upward water movement, the imbibition rate of shales with T -direction fractures will decrease suddenly after the bottom layer in contact with water is saturated during the initial period. This wetting phase movement (WPM) model can simulate 3D porous media with 2D fractures. The rate of imbibition by fractured porous media is associated with physical parameters such as porosity and fracture distribution (e.g., the number and angle of fractures). Using Monte Carlo methods, we examined fracture parameters and predicted elapsed time and cumulative water imbibition, for the Barnett Shale samples. The results show that the rate of imbibed water mass is sensitive to the number of fractures directly connected to water source, and the connectivity between two neighboring grid cells is a key parameter for the wetting-front progression. The findings of this study can help to better understand the imbibition process with multiple influencing processes and factors in fractured-matrix rocks. Although the experiments, data simulation, and prediction results are based only on Barnett Shale samples, the model is readily applicable to imbibition tests of other fractured rocks to show the spatial and temporal behavior during a dynamic imbibition process that are not easily captured experimentally.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

The effect of Ni doping on the mechanical behavior of tungsten

The effect of nickel (Ni) on activated sintering of tungsten has been known and investigated for decades. However, there are few reports on the mechanical properties of tungsten when Ni is added as a low alloying additive with less than 1 wt%. In this work, the mechanical behaviors of tungsten doped with 0.2–1.0 wt% nickel from room temperature up to 400 °C were investigated. The results show that the compression ductility of as-sintered Ni doped tungsten is drastically higher than that of as-sintered pure tungsten at all tested temperatures including room temperature, and the fracture toughness at room temperature is increased by 92%. The results suggest that the ductile-to-brittle transition temperature (DBTT) of tungsten can be reduced substantially by doping with Ni.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Possible role of crustal flexure in the initial detachment of extensional allochthons

The existence of low-angle normal faults indicates that the ratio of shear stress (TAU) to normal stress (sigma sub N) needed to cause slip on faults is substantially less than would be predicted based on experimental data. Because the tensional strength of rock at a large scale is exceedingly low, the upper plate of a low-angle normal fault cannot be pulled down the fault ramp, but must be driven down it by its own weight. The active or recently active Sevier Desert detachment fault in western Utah dips regionally at 12 deg. The radio of shear stress to normal stress due to the weight of the upper plate on a 12 deg dipping fault surface is 0.2. In contrast, laboratory experiments indicate that slip on fracture surfaces occurs with almost all rock types when (tau/sigma) reaches values of 0.6 to 0.85, corresponding to normal-fault dips of 30 deg to 40 deg. Seismological data indicate that low deviatoric stresses are associated with movement on faults of other geometrics and are not unique to low-angle normal faults. It thus appears that approximately planar fault zones with surface areas of hundreds to thousands of square kilometers have different mechanical properties than would be predicted based on laboratory studies of fractured rock. Modeling of stresses indicates that deviatoric stresses greater than 5kb exist and are sustainable in oceanic lithosphere, and that failure occurs when tau/sigma sub N approaches 0.6 to 0.85.

Spencer, J. E.↗

DOE OSTI2021

Creep Behavior of a High-$\gamma^{\prime}$ Ni-Based Superalloy Fabricated via Electron Beam Melting

Additive manufacturing enables the fabrication of complex engineering components previously inaccessible through traditional processes. Nickel-base superalloys with large γ' volume fraction are typically considered non-weldable and therefore exhibit a propensity for cracking during the fusion process. These crack-prone materials, however, are of great importance in gas turbine engines due to their excellent high temperature creep resistance. In this study we investigate the creep behavior of IN738LC produced by the electron beam melting process. Here, we find that with appropriate post-build heat treatment the creep response of material oriented in the build direction exhibits deformation and rupture behavior comparable to that of conventionally cast IN738 & IN738LC. In the transverse direction properties fall below the expected cast behavior, however, we argue this is likely due to differences in grain scale and crystallographic texture. It may be possible to coarsen the grain morphology with appropriate process-parameter optimization in order to reduce the severity of intergranular fracture in the transverse direction. These results illustrate that high temperature properties exhibited by additively manufactured IN738LC are suitable for the hot section of gas turbine engines.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Space Radiation Effects on Graphite-Epoxy Composite Materials

Radiation effects on engineering properties, dimensional stability, and chemistry on state of the art composite systems were characterized. T300/934 graphite-epoxy composite was subjected to 1.0 MeV electron radiation for a total dose of 1.0 x 10(10) rads at a rate of 5.0 x 10(7) rads/hour. This simulates a worst case exposure equivalent to 30 years in space. Mechanical testing was performed on he 4-ply unidirectional laminates over the temperature range of -250 F (116K) to +250 F (394K). A complete set of in-plane tensile elastic and strength properties were obtained (E sub 1, E sub 2, nu sub 12, G sub 12, X sub T, Y sub T, and S). In addition electron microscopy was used to study and analyze the fracture surfaces of all specimens tested. Results indicate that little difference in properties is noted at room temperature, but significant differences are observed at both low and elevated temperatures.

Milkovich, S. M.↗

DOE OSTI2021

Nonlinear elastodynamic behavior of intact and fractured rock under in-situ stress and saturation conditions

Not provided.

Materials Science↗

NASA NTRS2016

Multifunctional Hybrid Carbon Nanotube/Carbon Fiber Polymer Composites

For aircraft primary structures, carbon fiber reinforced polymer (CFRP) composites possess many advantages over conventional aluminum alloys due to their light weight, higher strengthand stiffness-to-weight ratio, and low life-cycle maintenance costs. However, the relatively low electrical and thermal conductivities of CFRP composites fail to provide structural safety in certain operational conditions such as lightning strikes. Despite several attempts to solve these issues with the addition of carbon nanotubes (CNT) into polymer matrices, and/or by interleaving CNT sheets between conventional carbon fiber (CF) composite layers, there are still interfacial problems that exist between CNTs (or CF) and the resin. In this study, hybrid CNT/CF polymer composites were fabricated by interleaving layers of CNT sheets with Hexcel® IM7/8852 prepreg. Resin concentrations from 1 wt% to 50 wt% were used to infuse the CNT sheets prior to composite fabrication. The interlaminar properties of the resulting hybrid composites were characterized by mode I and II fracture toughness testing (double cantilever beam and end-notched flexure test). Fractographical analysis was performed to study the effect of resin concentration. In addition, multi-directional physical properties like thermal conductivity of the orthotropic hybrid polymer composite were evaluated. Interleaving CNT sheets significantly improved the in-plane (axial and perpendicular direction of CF alignment) thermal conductivity of the hybrid composite laminates by 50 - 400%.

Kang, Jin Ho↗

DOE OSTI2020

Simulation of coupled multiphase flow and geomechanics in porous media with embedded discrete fractures

In fractured natural formations, the equations governing fluid flow and geomechanics are strongly coupled. Hydrodynamical properties depend on the mechanical configuration, and they are therefore difficult to accurately resolve using uncoupled methods. In recent years, significant research has focused on discretization strategies for these coupled systems, particularly in the presence of complicated fracture network geometries. In this work, we explore a finite-volume discretization for the multiphase flow equations coupled with a finite-element scheme for the mechanical equations. Fractures are treated as lower dimensional surfaces embedded in a background grid. Interactions are captured using the embedded discrete fracture model (EDFM) and the embedded finite element method (EFEM) for the flow and the mechanics, respectively. This nonconforming approach significantly alleviates meshing challenges. EDFM considers fractures as lower dimension finite volumes that exchange fluxes with the rock matrix cells. The EFEM method provides, instead, a local enrichment of the finite-element space inside each matrix cell cut by a fracture element. Both the use of piecewise constant and piecewise linear enrichments are investigated. They are also compared to an extended finite element approach. One key advantage of EFEM is the element-based nature of the enrichment, which reduces the geometric complexity of the implementation and leads to linear systems with advantageous properties. Synthetic numerical tests are presented to study the convergence and accuracy of the proposed method. It is also applied to a realistic scenario, involving a heterogeneous reservoir with a complex fracture distribution, to demonstrate its relevance for field applications.

58 GEOSCIENCES↗

DOE OSTI2022

High strain-rate compression behavior of polymeric rod and plate Kelvin lattice structures

The compressive high strain-rate behavior of polymeric Kelvin lattice structures with rod-based or plate-based unit cells was investigated through experimental techniques and finite element simulations. Polymeric lattice structures with 5x5x5 unit cell geometries were manufactured on the millimeter scale using vat polymerization additive manufacturing and tested at low (0.001/s) and high (1000/s) strain-rates. High strain-rate experiments were performed and validated for a viscoelastic split-Hopkinson (Kolsky) pressure bar system (SHPB) coupled with high-speed imaging and digital image correlation (DIC). Experimental results at both low and high strain-rates show the formation of a localized deformation band which was more prevalent in low relative density specimens and low strain-rate experiments. Strain-rate effects of lattice specimens strongly correlate with effects of the base polymer material; both bulk polymer and lattice specimen demonstrated strain-rate hardening, strain-rate stiffening, and decreased fracture strain under dynamic loading. Results show mechanical failure properties and energy absorption depended strongly on the relative density of the lattice specimen and exhibited distinct scaling between relative density and geometry type (rod, plate) and loading rate. High relative density plate-lattices demonstrated inferior mechanical properties to rod-lattices; however, there exists a critical relative density for a given mechanical property (17%- 28%) below which plate-lattices outperform rod-lattices of similar mass. As a result, high strain-rate explicit finite element simulations were performed and showed good agreement with the mechanical failure trends and deformation modes observed in the experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Effect of Composition on Mechanical Properties and Conductivity of the Dual-Ion Conductor Na 1+ x Mn x /2 Zr 2– x /2 (PO 4 ) 3 for Solid-State Batteries

Here we report the dependence of mechanical properties and ionic conductivity of the Na 1+ x Mn x /2 Zr 2– x /2 (PO 4 ) 3 (designated as NMZP) ionic conductor on its composition (with x = 0.5, 1.0, 1.5, and 2.0). Local mechanics was studied by instrumented nanoindentation, and the properties of interest included the elastic modulus, hardness, and fracture toughness. Overall, the material becomes more compliant and soft with the increase in the Na content. The elastic modulus reduces from 120 to 80 GPa, and nanoindentation hardness reduces from 7.8 to 4.2 GPa when x changes from 0.5 to 2.0. The relationship with fracture toughness ( K C ) is highly nonlinear: fracture toughness first decreases and then increases with the increase in the sodium content, reaching a maximum value of 0.89 MPa × m 1/2 at x = 2.0. Such a relationship was found to correlate with the formation of a glassy phase in NMZP at intermediate Na concentration. The maximum ionic conductivity coincides with the maximum fracture toughness in this material.

25 ENERGY STORAGE↗

DOE OSTI2021

Precambrian Crystalline Basement Properties From Pressure History Matching and Implications for Induced Seismicity in the US Midcontinent

Injection-induced seismicity across the US midcontinent has almost exclusively occurred in the crystalline basement that underlies the Arbuckle Group aquifer and its equivalents, the primary wastewater disposal zone in this region. However, the properties of the basement are not well known. Newly compiled data, from Class I wells in Kansas, provide a unique record of pressures in the Arbuckle and an opportunity to constrain the reservoir-scale properties of the basement such as permeability, diffusivity, and specific storage. Constraints on these parameters are critical for modeling fluid flow and pressures across the entire Arbuckle-basement system, and are necessary for accurate evaluation and prediction of injection-induced earthquakes. Here, we present a detailed, three-dimensional geological and pressure history-matched numerical model for the Arbuckle and basement, based on data from >400 wells covering a large region in south-central Kansas, where injection-induced seismicity has been concentrated since 2014. Simulations of dynamic data from 319 wells indicate that Arbuckle pressures have increased by 1.1 MPa in high injection rate areas and an overpressure of <0.1 MPa may be the cause of seismicity in the basement. Pressure-history matching also yields the likely range in porosity (0.3%–7%), permeability (0.1–0.7 mD), and diffusivity (0.004–0.07 m2 /s) for the basement. The resulting estimates suggest reservoir-scale properties of the basement are enhanced by faults and fractures. Importantly, the diffusivities determined in this study are lower than estimates derived from Kansas earthquake triggering fronts, and suggest that such seismicity-based techniques may have limitations, particularly where spacetime patterns between injection and seismicity are complex.

58 GEOSCIENCES↗

DOE OSTI2023

Using Artificial Microstructures to Understand Microstructure Property Relationship-Toughening Mechanisms in Metallic Glass (Final Report)

Metallic glasses are a new class of structural materials which exhibit exciting mechanical properties including high strength and elasticity. In terms of fracture toughness, the material class of metallic glasses spans a wide range; Some metallic glasses are extremely brittle and exhibit near ideal brittle behavior whereas others can be exceptional tough with values comparable to the toughest metals out there. Such large range of observed fracture toughness within the material class of metallic glasses is surprising as they have seemingly a very similar atomic structure. Therefore, we developed “artificial microstructures” which allows to decouple the various contribution of sample geometry, imperfection and structure. Specifically, we decouple variations in the alloys’ chemical composition and the atomic structure and quantified the resulting fracture toughness. Atomic structure of a metallic glass can be modified by the fictive temperature. The fictive temperature of a glass is the temperature at which the liquid metallic glass falls out of equilibrium upon colling and forms a glass. Upon further cooling the structure is maintained only thermal oscillations decrease due to a lower absolute temperature. We found that the effect of fictive temperature (same chemistry, different structural stages of the glass) is comparable to the variations of fracture toughness when the chemistry is varied. Hence, it appears that the subtle differences in the glass structure are responsible for the large range of fracture toughness’s observed. Our results reveal that fracture toughness within the material class of metallic glasses varies significantly and we found some example alloys with exceptional high resistance to fracture and others that are almost ideally brittle. Significant influences on the fracture toughness have the structure of the glass, its chemistry, and some imperfections in the structure.

36 MATERIALS SCIENCE↗

NASA NTRS1971

An experimental study of the mechanism of failure of rocks under borehole jack loading

Laboratory and field tests with an experimental jack and an NX-borehole jack are reported. The following conclusions were made: Under borehole jack loading, a circular opening in a brittle solid fails by tensile fracturing when the bearing plate width is not too small. Two proposed contact stress distributions can explain the mechanism of tensile fracturing. The contact stress distribution factor is a material property which can be determined experimentally. The borehole tensile strength is larger than the rupture flexural strength. Knowing the magnitude and orientation of the in situ stress field, borehole jack test results can be used to determine the borehole tensile strength. Knowing the orientation of the in situ stress field and the flexural strength of the rock substance, the magnitude of the in situ stress components can be calculated. The detection of very small cracks is essential for the accurate determination of the failure loads which are used in the calculation of strengths and stress components.

Van, T. K.↗

NASA NTRS1974

Stress corrosion cracking of titanium alloys

The effect of hydrogen on the properties of metals, including titanium and its alloys, was investigated. The basic theories of stress corrosion of titanium alloys are reviewed along with the literature concerned with the effect of absorbed hydrogen on the mechanical properties of metals. Finally, the basic modes of metal fracture and their importance to this study is considered. The experimental work was designed to determine the effects of hydrogen concentration on the critical strain at which plastic instability along pure shear directions occurs. The materials used were titanium alloys Ti-8Al-lMo-lV and Ti-5Al-2.5Sn.

Statler, G. R.↗

NASA NTRS1985

Tough composite materials: Recent developments

The present volume broadly considers topics in composite fracture toughness and impact behavior characterization, composite system constituent properties and their interrelationships, and matrix systems' synthesis and characterization. Attention is given to the characterization of interlaminar crack growth in composites by means of the double cantilever beam specimen, the characterization of delamination resistance in toughened resin composites, the effect of impact damage and open holes on the compressive strength of tough resin/high strain fiber laminates, the effect of matrix and fiber properties on compression failure mechanisms and impact resistance, the relation of toughened neat resin properties to advanced composite mechanical properties, and constituent and composite properties' relationships in thermosetting matrices. Also treated are the effect of cross-link density on the toughening mechanism of elastomer-modified epoxies, the chemistry of fiber/resin interfaces, novel carbon fibers and their properties, the development of a heterogeneous laminating resin, solvent-resistant thermoplastics, NASA Lewis research in advanced composites, and opportunities for the application of composites in commercial aircraft transport structures.

Vosteen, L. F.↗

NASA NTRS1987

The acousto-ultrasonic approach

The nature and underlying rationale of the acousto-ultrasonic approach is reviewed, needed advanced signal analysis and evaluation methods suggested, and application potentials discussed. Acousto-ultrasonics is an NDE technique combining aspects of acoustic emission methodology with ultrasonic simulation of stress waves. This approach uses analysis of simulated stress waves for detecting and mapping variations of mechanical properties. Unlike most NDE, acousto-ultrasonics is less concerned with flaw detection than with the assessment of the collective effects of various flaws and material anomalies. Acousto-ultrasonics has been applied chiefly to laminated and filament-wound fiber reinforced composites. It has been used to assess the significant strength and toughness reducing effects that can be wrought by combinations of essentially minor flaws and diffuse flaw populations. Acousto-ultrasonics assesses integrated defect states and the resultant variations in properties such as tensile, shear, and flexural strengths and fracture resistance. Matrix cure state, porosity, fiber orientation, fiber volume fraction, fiber-matrix bonding, and interlaminar bond quality are underlying factors.

Vary, Alex↗

NASA NTRS1988

The acousto-ultrasonic approach

Vary, Alex↗