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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

In Situ Synchrotron X-ray Diffraction Investigations of the Nonlinear Deformation Behavior of a Low Modulus β -Type Ti36Nb5Zr Alloy

The low modulus β-type Ti alloys usually have peculiar deformation behaviors due to their low phase stability. However, the study of the underlying mechanisms is challenging since some physical mechanisms are fully reversible after the release of the load. In this paper, the deformation behavior of a low modulus β-type Ti36Nb5Zr alloy was investigated with the aid of in situ synchrotron X-ray diffraction (SXRD) during tensile loading. The evolution of lattice strains and relative integrated diffraction peak intensities of both the β and α” phases were analyzed to determine the characteristics of the potential deformation mechanisms. Upon loading, the α” diffraction spots appeared at specific azimuth angles of the two-dimensional SXRD patterns due to the <110> fiber texture of original β grains and the selection of favorable martensitic variants. The nonlinear deformation behavior originated from a reversible stress-induced martensitic transformation (SIMT). However, the SIMT contributed a little to the large recoverable strain of over 2.0%, which was dominated by the elastic deformation of the β phase. Various deformation mechanisms were activated successively at different applied strains, including elastic deformation, SIMT and plastic deformation. Our investigations provide in-depth understandings of the deformation mechanisms in β-type Ti alloys with low elastic modulus.

36 MATERIALS SCIENCE↗
NASA NTRS1990

Tensile and compressive failure modes of laminated composites loaded by fatigue with different mean stress

Laminated composite materials tend to fail differently under tensile or compressive load. Under tension, the material accumulates cracks and fiber fractures, while under compression, the material delaminates and buckles. Tensile-compressive fatigue may cause either of these failure modes depending on the specific damage occurring in the laminate. This damage depends on the stress ratio of the fatigue loading. Analysis of the fatigue behavior of the composite laminate under tension-tension, compression-compression, and tension-compression had led to the development of a fatigue envelope presentation of the failure behavior. This envelope indicates the specific failure mode for any stress ratio and number of loading cycles. The construction of the fatigue envelope is based on the applied stress-cycles to failure (S-N) curves of both tensile-tensile and compressive-compressive fatigue. Test results are presented to verify the theoretical analysis.

Rotem, Assa↗
DOE OSTI2020

Mechanical Properties and Deformation Behavior of Additively Manufactured 316L Stainless Steel (FY2020)

The Transformational Challenge Reactor (TCR) program plans to build most of the TCR core components through additive manufacturing (AM) processes. These processes include laser powder bed fusion (LPBF) for the metallic (316L) components and the newly developed combined process of binderjet printing and chemical vapor infiltration (CVI) for the SiC fuel matrix. Mechanical testing and characterization tasks have been carried out since the beginning of the TCR program to (1) build a property database for the AM materials that will be used in TCR core and (2) to assess the materials’ performance in TCR-relevant conditions. This document reports the outcome of the testing and characterization efforts for the fiscal year with a focus on the mechanical performance data of AM 316L stainless steel (SS). Baseline tensile testing over a wide temperature range of room temperature–600 °C was completed for the AM 316L alloy in as-built, stress-relieved, and solution-annealed conditions. The as-built 316L showed the highest strength, and the alloy after the post-build treatments showed reduced strengths in the low-strain range. However, the strength differences among the AM materials became insignificant in the later part of deformation. Furthermore, regardless of post-build processing, the AM 316L SS showed higher strength and comparable ductility when compared with wrought 316L SS. Thermal creep testing and microstructural evolution during creep deformation were also performed under selected conditions. It was found that the AM 316L steel showed the best creep resistance in the stress-relieved condition. In-situ tensile tests were performed using scanning electron microscopy and 1-ID beamline at the Advanced Photon Source to elucidate the deformation and fracture behavior of AM 316L and the evolution of crystalline stress, dislocations, and pore distribution. Using these in-situ testing data, an in-depth analysis of the roles of microstructural features in deformation and fracture processes is presented herein. The final section of the document introduces ongoing and future activities for materials testing and characterization, including irradiation effect studies and ball punch testing on AM 316L and AM IN718 alloys.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Carburization and decarburization behavior of Grade 91 ferritic-martensitic steel in liquid sodium environments

Here, this paper presents a study of carbon transfer and its effect on microstructure and tensile properties of Grade 91 (G91) ferritic-martensitic steel exposed to sodium at 550–650 °C. Sodium exposure tests were conducted in Argonne's forced convection sodium loops up to exposure times of ~40,000 h. Thermal aging study of G91 steel was conducted in parallel to isolate the thermal aging effect from the sodium effect. It was found that sodium exposures at 650 °C dissolved M 23 C 6 carbides, eliminated the martensite subgrain structure resulting in excessive grain growth and reduced the tensile strength by >50%, while sodium exposures at 550 and 600 °C had an insignificant effect on its microstructure and tensile properties. These effects were attributed to the carburization/decarburization process of G91 steel in sodium environments. Carbon concentrations in sodium were determined by a foil equilibration method. The estimated carbon concentration was in the range of 0.8–1.2 ppm in the SMT-1 loop and 0.3–0.7 ppm in the SMT-2 loop. Thermodynamic analysis of the carburization – decarburization process was conducted for G91 steels exposed in sodium environments. The carbon activity-concentration relationship for G91 was evaluated by considering four phases in G91, i.e. bcc ferrite, M 23 C 6 , NbC and VC carbides. It was found that the carburization-decarburization process in G91 steel was dictated by M 23 C 6 carbides at high carbon activities, while NbC and VC carbides dominated the process at low carbon activities. The calculated carburization-decarburization boundary showed that G91 would undergo decarburization at 650 °C and carburization at 550 °C in the sodium loop environments, which was consistent with our experimental observations. This experimental and theoretical analysis provided a basis for predicting the effect of carbon transfer on the integrity of reactor components in sodium environments and for the design of new alloys used in sodium-cooled fast reactors.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Understanding Fundamental Mechanisms Behind Anomalous Segregation Behavior at Grain Boundaries during Diffusional Creep

Recent experimental studies in a nickel (Ni)-rhenium (Re) alloy demonstrated anisotropic elemental segregation around grain boundaries (GBs) while under tensile strain. Some GBs showed Re enrichment, while others showed Re depletion. We hypothesize that differing vacancy fluxes to GBs, caused by the anisotropic elastic stresses generated within the polycrystal, results in anisotropic creep-induced segregation (CIS) and grain growth. Using molecular dynamics simulations, we developed a mechanistic understanding of CIS and determined the contribution of elastic stresses and grain growth in Ni-Re alloys. We find that the stress state of the GB significantly changes the segregation energy profile for Re atoms, leading to significant Re redistribution. Further, as the GB migrates, the segregation/desegregation tendency of Re leads to bands of Re enrichment/depletion. Our results have important consequences for the quantitative predictions of diffusion creep and for the design of high-temperature creep-resistant Ni alloys.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Elucidating the impact of stress states on grain boundary passivation in Ni-5Cr using the Rhines pack method

The oxidation behavior of a Ni–5Cr (at.%) alloy was evaluated at 420 ° C using the Rhines pack method and simultaneous tensile and compressive stress states via a miniature four-point bending fixture. At this moderate temperature, grain boundaries dominate mass transport and the resulting oxidation response. Oxidation produced approximately 1μ⁢m-wide protective Cr 2 O 3 films capping some grain boundaries and penetrative, intergranular Cr-rich oxides at other grain boundaries. Externally applied tensile and compressive stress during oxidation increased the prevalence of Cr 2 O 3 cap formation compared to no applied stress, with tensile stress resulting in more Cr 2 O 3 caps than compressive stress. The observed oxide cap morphology was similar across all test conditions. Regions under compressive stress showed an order of magnitude greater Cr depletion depth along the grain boundary. Chromium nitrides (CrN), likely from N contamination of the Rhines pack cell, were observed both at the oxide–metal interface and intergranularly within the alloy. Collectively these results demonstrate that applied stress promotes localized protective oxide cap formation over grain boundaries, with compressive stress additionally promoting deeper Cr depletion. Furthermore the experimental approach helped separate out the effects of stress on local oxide formation and grain boundary passivation.

4 point bend↗
DOE OSTI2023

A statistical mechanics framework for polymer chain scission, based on the concepts of distorted bond potential and asymptotic matching

To design increasingly tough, resilient, and fatigue-resistant elastomers and hydrogels, the relationship between controllable network parameters at the molecular level (bond type, non-uniform chain length, entanglement density, etc.) to macroscopic quantities that govern damage and failure must be established. Many of the most successful constitutive models for elastomers have been rooted in statistical mechanical treatments of polymer chains. Typically, such constitutive models have used variants of the freely jointed chain model with rigid links. However, since the free energy state of a polymer chain is dominated by enthalpic bond distortion effects as the chain approaches its rupture point, bond extensibility ought to be accounted for if the model is intended to capture chain rupture. To that end, a new bond potential is supplemented to the freely jointed chain model (as derived in the u FJC framework of Buche and Silberstein (2021) and Buche et al. (2022)), which we have extended to yield a tractable, closed-form model of single chain behavior that should be amenable to continuum-level constitutive model development. Inspired by the asymptotically matched u FJC model response in both the low/intermediate chain force and high chain force regimes, a simple, quasi-polynomial bond potential energy function is derived. This bond potential exhibits harmonic behavior near the equilibrium state and anharmonic behavior for large bond stretches tending to a characteristic energy plateau (akin to the Lennard-Jones and Morse bond potentials). Using this bond potential, approximate yet highly-accurate analytical functions for bond stretch and chain force dependent upon chain stretch are established. Then, using this polymer chain model, a stochastic thermal fluctuation-driven chain rupture framework is developed. This framework is based upon a force-modified tilted bond potential that accounts for distortional bond potential energy, allowing for the derivation and subsequent calculation of the dissipated chain scission energy. Here, the cases of rate-dependent and rate-independent scission are accounted for throughout the rupture framework. The impact of Kuhn segment number on chain rupture behavior is also investigated. The model is fit to single chain mechanical response data collected from atomic force microscopy tensile tests for validation and to glean deeper insight into the molecular physics taking place. Due to their analytical nature, this polymer chain model and the associated rupture framework can in the future be implemented in finite element models accounting for fracture and fatigue in polydisperse elastomer networks.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Dynamic data-driven multiscale modeling for predicting the degradation of a 316L stainless steel nuclear cladding material

Here, we have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Utilizing integrated neutron diffraction and elastoplastic self-consistent crystal plasticity model to quantitatively assess the strengthening mechanism in Al–12.5Ce and Al–12.5Ce–0.4Mg alloys

An integrated in-situ neutron diffraction and elastic plastic self-consistent crystal plasticity (EPSC-CP) modeling scheme is performed on a binary Al–12Ce alloy and a ternary Al–12Ce–0.4Mg alloys. Using this scheme, the constitutive parameters, i.e. elastic constants and slip system parameters of individual phases can be calibrated which can be used in microstructure-based CP models to predict materials performance. From this study, it is shown that the elastic constants of Al 11 Ce 3 intermetallics calculated from density function theory calculation in the literature are rather accurate. When applied to the EPSC-CP model, the lattice strains of both the binary and ternary alloys are correctly predicted as compared with experiments, and large lattice strain differences between Al (100) plane and Al 11 Ce 3 (010) plane are demonstrated. The slip system parameters calibrated by the scheme shows that the addition of 0.4 wt% Mg in the alloy has little influence on the critical resolved shear stress of initial dislocation glide in the Al matrix which caused plastic yield in the material. This can be explained by the very dilute Mg solute content in the Al solid solution, causing large spacing of Al–Mg lattice misfit sites and little impact on resistance of dislocation glide at initial yield. The 0.4 wt% Mg addition, on the other hand, has a large influence on the hardening term in the slip system parameters, indicating those Al–Mg misfit sites do help dislocation accumulation during the deformation. The impact of dilute Mg addition on the Al slip system parameters is also reflected in the flow behavior of the ternary alloy: little impact on the yield stress, but a large impact on working hardening and tensile strength of the materials which is consistent with the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Dynamic Data-Driven Multiscale Modeling for Predicting Microstructure and Mechanical Properties of 316L Stainless Steel

We have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Metallurgical characterization of the fracture of several high strength aluminum alloys

The fracture behavior for structural aluminum alloys (2024, 6061, 7075, and 7178) was examined in selected heat treatments. The investigation included tensile, shear, and precracked notch-bend specimens fractured at ambient temperature under monotonic loading. Specimens were obtained from thin sheets and thick plates and were tested in longitudinal and transverse orientations at different strain rates. Microstructures of alloys were examined using the optical microscope and the scanning electron microscope with associated energy dispersive X ray chemical analysis. Several different types of second phase particles, some not reported by other investigators, were identified in the alloys. Fracture morphology was related to microstructural variables, test variables, and type of commercial product. Specimen orientation examined in the present investigation had little effect on fracture morphology. Test strain rate changes resulted in some change in shear fracture morphology, but not in fracture morphology of tensile specimens.

Bhandarkar, M. D.↗
DOE OSTI2025

Machine Learning based Correlation of the Mechanical Properties of Sub-sized and Standard-sized Specimens

Mechanical testing with sub-sized specimens is essential in the nuclear industry, offering the ability to conduct tests in confined spaces with lower irradiation and expediting material qualification. However, smaller specimens exhibit different material behavior across scales, a phenomenon known as the "specimen size effect". In this study, we compiled over 1,000 tensile testing records, covering 54 parameters such as material type, composition, manufacturing details, irradiation conditions, specimen dimensions, and tensile properties through a comprehensive literature review. We focus on correlating sub-sized and standard specimens’ tensile mechanical properties on SS316 alloy, which has the most extensive dataset available. We explore ML-based models and uncertainty quantification for tensile properties, analyze key factors influencing these properties, and compare the effectiveness of ML models with existing analytical methods in addressing the specimen size effect.

tensile properties↗
NASA NTRS1994

Modeling of stress/strain behavior of fiber-reinforced ceramic matrix composites including stress redistribution

A computational simulation procedure is presented for nonlinear analyses which incorporates microstress redistribution due to progressive fracture in ceramic matrix composites. This procedure facilitates an accurate simulation of the stress-strain behavior of ceramic matrix composites up to failure. The nonlinearity in the material behavior is accounted for at the constituent (fiber/matrix/interphase) level. This computational procedure is a part of recent upgrades to CEMCAN (Ceramic Matrix Composite Analyzer) computer code. The fiber substructuring technique in CEMCAN is used to monitor the damage initiation and progression as the load increases. The room-temperature tensile stress-strain curves for SiC fiber reinforced reaction-bonded silicon nitride (RBSN) matrix unidirectional and angle-ply laminates are simulated and compared with experimentally observed stress-strain behavior. Comparison between the predicted stress/strain behavior and experimental stress/strain curves is good. Collectively the results demonstrate that CEMCAN computer code provides the user with an effective computational tool to simulate the behavior of ceramic matrix composites.

Mital, Subodh K.↗
NASA NTRS1976

Finite element solutions for crack-tip behavior in small-scale yielding

The subject considered is the stress and deformation fields in a cracked elastic-plastic power law hardening material under plane strain tensile loading. An incremental plasticity finite element formulation is developed for accurate analysis of the complete field problem including the extensively deformed near tip region, the elastic-plastic region, and the remote elastic region. The formulation has general applicability and was used to solve the small scale yielding problem for a set of material hardening exponents. Distributions of stress, strain, and crack opening displacement at the crack tip and through the elastic-plastic zone are presented as a function of the elastic stress intensity factor and material properties.

Tracey, D. M.↗
DOE OSTI2024

Effects of size, geometry, and testing temperature on additively manufactured Ti-6Al-4V titanium alloy

This article presents a comprehensive study concerning size and geometry effect on the ambient and high-temperature mechanical behavior of additively manufactured laser powder bed fusion Ti-6Al-4V alloy. Key mechanical property metrics are presented, including strain hardening rate, yield strength, and Young’s modulus as a function of thickness and testing temperature (ambient, 250 °C, and 450 °C). Here, the effect of specimen size on manufacturing-induced microstructural feature formation is demonstrated and discussed. A detailed analysis regarding Young’s modulus, yield strength, and strain hardening rate variation at elevated temperatures is also presented. Size effect and temperature-sensitive deformation mechanisms are linked to the underlying microstructural deformation mechanisms activated at respective temperatures. Counter-intuitively, this study determined that irrespective of the geometry, strain hardening rates increased as temperature increased. An in-depth microstructural examination is presented to explain the stated observation. The texture of Interrupted tensile test samples examined for ambient, 250 °C, and 450 °C post-yield was observed to be unchanged, indicating the strain hardening behavior was not texture dependent. Schmid factor analysis, coupled with experimental findings from previous work, was implemented to generate a hypothesis. This hypothesis suggests that the drop in critical resolved shear stress for basal and pyramidal slip systems, as temperature increases, paired with the high dislocation density of laser powder bed fusion Ti-6Al-4V, leads to dislocation entanglement and results in increased strain hardening at elevated temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Linking constituent phase properties to ductility and edge stretchability of two DP 980 steels

Two DP 980 steels were characterized with multiple methods to determine its microstructure characteristics, tensile properties and edge stretchability. The first (DP980-B) is a commercial grade DP980 steel produced by AK Steel, while the second (DP980-T) is a modification of the first one by a tempering process. Both contain two individual phases: ferrite and martensite with body centered cubic (BCC) and tetragonal (BCT) crystal structure respectively. ASTM standard tensile tests were performed for both materials, revealing that DP980-B has higher work hardening and larger total elongation than DP980-T. Standard hole piercing and subsequent hole expansion and extrusion tests were also performed. The critical hole expansion ratio (HER) of hole pierced sheet at different nominal clearances, on the other hand, show an opposite trend: the HER of DP980-T almost doubles that of DP980-B. This indicates the tensile ductility and edge stretchability are determined by different mechanisms due to different deformation modes. The ductility of sheet metal during uniaxial tension is determined by deformation instability, i.e. necking, due to less constraint at the region of deformation and fracture will occur quickly after necking. The contribution of post-necking deformation to the total elongation is insignificant for the high strength grades such as DP980 steels. The ductility during hole-expansion, however, is mainly determined by material fracture behavior that is dependent on phase property disparity and material intrinsic fracture parameters. With the individual phase properties for both DP steels determined by in situ tensile tests under high energy X-ray diffraction, the results show that DP980-T steel has lower property disparities between the two phases than DP980-B steel, due to the tempering process. This explains why the DP980-T steel has higher HER than DP980-B steel: lower phase disparity will lead to less local deformation during loading. The higher work hardening rate for DP980-B steel contributes to its higher uniform elongation compared with DP980-T steel based on the maximum load condition of deformation instability. An integrated finite element simulation framework for studying hole expansion is also presented here, based on the calculated individual phase properties from the combined high energy x-ray diffraction (HEXRD) and elastic plastic self-consistent modeling. The simulation results correlate well with the experimental results on the HER difference between the two materials.

36 MATERIALS SCIENCE↗
NASA NTRS1994

In Situ Radiography During Tensile Tests

Laboratory system for testing specimens of metal-, ceramic-, and intermetallic-matrix composite materials incorporates both electromechanical tensile-testing subsystem and either of two imaging subsystems that take x-ray photographs of specimens before, during, and after tensile tests. Used to test specimens of reaction-bonded silicon nitride reinforced with silicon carbide fibers (SiC/RBSN) considered for high-temperature service in advanced aircraft turbine engines. Provides data on effects of preexisting flaws (e.g., high-density impurities and local variations of density) on fracture behavior. Accumulated internal damage monitored during loading. X-ray source illuminates specimen in load frame while specimen is pulled. X-ray images on film correlated with stress-vs.-strain data from tensile test.

Baaklini, George Y.↗
DOE OSTI2023

Characterization of CNC Nanoparticles Prepared via Ultrasonic-Assisted Spray Drying and Their Application in Composite Films

The ultrasonic-assisted spray dryer, also known as a nano spray dryer and predominantly used on a lab scale in the pharmaceutical and food industries, enables the production of nanometer-sized particles. In this study, the nano spray dryer was applied to cellulosic materials, such as cellulose nanofibrils (CNFs) and cellulose nanocrystals (CNCs). CNC suspensions were successfully dried, while the CNF suspensions could not be dried, attributable to their longer fibril lengths. The nano spray drying process was performed under different drying conditions, including nebulizer hole sizes, solid concentrations, and gas flow rates. It was confirmed that the individual particle size of nano spray-dried CNCs (nano SDCNCs) decreased as the nebulizer hole sizes and solid contents of the suspensions decreased. The production rate of the nano spray dryer increased with higher solid contents and lower gas flow rates. The resulting nano SDCNCs were added to a polyvinyl alcohol (PVA) matrix as a reinforcing material to evaluate their reinforcement behavior in a plastic matrix using solvent casting. After incorporating the 20 wt.% nano SDCNCs into the PVA matrix, the tensile strength and tensile modulus elasticity of the neat PVA nanocomposite film increased by 22% and 32%, respectively, while preserving the transparency of the films.

36 MATERIALS SCIENCE↗