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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Anisotropic spall failure of additively manufactured 316L stainless steel

The dynamic high strain rate tensile (spall) failure of additively manufactured (AM) materials is an area of great interest but much less understood than material failure under other loading regimes. The research presented here examines the effects of microstructure anisotropy in 316L stainless steel fabricated by laser powder bed fusion (LPBF) on its spall failure and properties. In this work, plate-on-plate impact experiments were performed using an 80-mm gas gun to investigate the spall behavior of AM fabricated sample discs with impact along the perpendicular and parallel orientations relative to build directions. Experiments were also performed on wrought 316L stainless steel as baseline material with uniform equiaxed grain microstructure for comparison with the AM material of same composition. The spall experiments involved free-surface velocity profiles measured using Photon Doppler Velocimetry (PDV) to capture the spall pull-back signals, combined with post-mortem analysis of the microstructure of soft-recovered impacted samples. In the case of AM samples, spall failure initiated preferentially at melt pool boundaries in both impact directions. The spall plane location and spall strength, however, were both heavily influenced by the orientation of the impact direction relative to the build direction in the AM samples. The spall behavior is also observed to be more complex in the samples impacted perpendicular to the build (through-thickness) direction, due in large part to the orientation of the microstructural features such as melt pool boundaries, laser scan tracks, and general grain morphology.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures

Design of large composite structures requires striking a balance between permitted flaw size,strength margins, weight, and production rate. Stringent requirements manufacturing flaws can result in a lightweight structure because the strength properties are assumed to be closer to pristine. However, these stringent requirements can lead to production delays due to increased inspection and rework needed during the layup and rejection of parts after cure. Conversely, permitting larger flaws can reduce production delays, but will likely result in a heavier structure due to increased conservatism needed to maintain acceptable structural margins. The tradeoff between these criteria can vary between different structures and material systems, so the balance between manufacturing and design requirements is always a moving target. Assessment of this tradeoff requires having the ability to quickly evaluate the impact of flaw size on strength margin across an entire structure for a large number of load cases. The approach taken in this work is to implement an effects of defects analysis and sizing framework within HyperX. HyperX performs optimization of composite structures; this capability has been enhanced to include structural flaw data in the margin of safety calculations performed during optimization. Both the flaw import process and analysis of flaws have been generalized such that any flaw type from any source can be considered. The resulting tool enables rapid assessment of the impact of defects both at a vehicle and part level.

Effects of defects↗
NASA NTRSDate not supplied

Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures

Design of large composite structures requires striking a balance between permitted flaw size,strength margins, weight, and production rate. Stringent requirements manufacturing flaws can result in a lightweight structure because the strength properties are assumed to be closer to pristine. However, these stringent requirements can lead to production delays due to increased inspection and rework needed during the layup and rejection of parts after cure. Conversely, permitting larger flaws can reduce production delays, but will likely result in a heavier structure due to increased conservatism needed to maintain acceptable structural margins. The tradeoff between these criteria can vary between different structures and material systems, so the balance between manufacturing and design requirements is always a moving target. Assessment of this tradeoff requires having the ability to quickly evaluate the impact of flaw size on strength margin across an entire structure for a large number of load cases. The approach taken in this work is to implement an effects of defects analysis and sizing framework within HyperX. HyperX performs optimization of composite structures; this capability has been enhanced to include structural flaw data in the margin of safety calculations performed during optimization. Both the flaw import process and analysis of flaws have been generalized such that any flaw type from any source can be considered. The resulting tool enables rapid assessment of the impact of defects both at a vehicle and part level.

Effects of defects↗
NASA NTRS1986

Impacts of free-floating objects: Unique space station experiments

The transfer of momentum and kinetic energy between planetary bodies forms the basis for wide ranging problems in planetary science ranging from the collective long term effects of minor perturbations to the catastrophic singular effect of a major collision. Although the collisional transfer of momentum and energy was discussed over the last two decades, major issues remain that largely reflect current limitations in Earth based experimental conditions and 3-D numerical codes. Two examples with potential applications in a Space Station laboratory, are presented: asteroid spin rates and orientations, and planetary disruption/spin rates. Asteroid spin rate and orientation experiments are needed wherein free floating nonspining and spining objects of varying strength, porosity, and volatility are impacted at varying velocities and angles. A space station platform also could provide an opportunity to test important facets of planetary disruption/spin rate models by allowing freely suspended spherical targets of varying viscosities, internal density gradients, and spin rates.

Schultz, P. H.↗
DOE OSTI2022

Evaluating Grid Strength under Uncertain Renewable Generation

The increasing displacement of synchronous generators with renewable resources such as wind and solar via power electronic interfaces causes a reduction in short-circuit strength and weak grid issues. The variation and uncertainty of renewable energy increase challenges for identifying weak grid conditions. This paper proposes an efficient method to analyze the impact of uncertain renewable energy on grid strength. The proposed method uses the probabilistic collocation method (PCM) to approximate the results of grid strength assessment under uncertain renewable generation, in order to reduce computational burden without compromising result accuracy when compared with traditional Monte Carlo simulation (MCS). To improve the accuracy of the approximation results, the proposed method integrates the K-means clustering technique with PCM to select the approximation samples of input variables. The efficacy of the proposed method is demonstrated by comparison with MCS on the modified IEEE 9-bus system and modified IEEE 39-bus system with multiple renewable generators.

grid strength↗
NASA NTRS2012

Some Examples of the Relations Between Processing and Damage Tolerance

Most structures made of laminated polymer matrix composites (PMCs) must be designed to some damage tolerance requirement that includes foreign object impact damage. Thus from the beginning of a part s life, impact damage is assumed to exist in the material and the part is designed to carry the required load with the prescribed impact damage present. By doing this, some processing defects may automatically be accounted for in the reduced design allowable due to these impacts. This paper will present examples of how a given level of impact damage and certain processing defects affect the compression strength of a laminate that contains both. Knowledge of the impact damage tolerance requirements, before processing begins, can broaden material options and processing techniques since the structure is not being designed to pristine properties.

Nettles, Alan T.↗
DOE OSTI2023

Material and component developments for the DEMO divertor using fibre reinforcement and additive manufacturing

Within the research along the European Fusion Roadmap, water-cooled divertor PFCs are foreseen in the design of a first fusion demonstration power plant (DEMO) in order to provide reliable heat removal capability. In the frame of this concerted attempt, the Max Planck Institute for Plasma Physics is concentrating on the development and testing of composite materials based on tungsten (W, preferred armour material) and copper (Cu, preferred heat sink material). W fibres (W f ) as monofilaments and yarns as reinforcement play a central role in these investigations due to their extraordinary properties concerning ductility already at room temperature and high tensile strength. Recent investigations on the impact of radiation damage suggest that the fibres retain their ductility upon irradiation. W reinforced with W fibres (W f /W) allows to overcome the intrinsic brittleness of W. Quantitative mechanical fracture tests of W f /W confirm the basic mechanisms of fibre reinforcement and the increased resistance to mechanical fatigue. The good wettability of W with liquid Cu and the absence of any metallurgical solubility make up an ideal material pairing for composite production. W fibre-reinforced Cu (W f /Cu) cooling tubes provide a rather high thermal conductivity (> 250 W mK -1 ) and at least twice the strength of CuCrZr in hoop direction in the temperature range up to at least 500 °C. Very recent neutron irradiation experiments confirm the sustainment of ductility of the W f /Cu composite. Numerical simulations suggest that thermal stresses in W-Cu PFCs could be strongly reduced by tailoring the local W and Cu volume fraction. This 'freely' distributed material composition can be achieved by means of additively manufactured W skeletons consecutively infiltrated by Cu. Investigations with W preforms produced by Laser Beam Powder Bed Fusion and infiltrated by Cu demonstrate the feasibility of this approach while testing of specifically prepared specimen is ongoing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

High-performance molded composites using additively manufactured preforms with controlled fiber and pore morphology

Here, large-scale multimaterial preforms produced by additive manufacturing (AM) underwent compression molding (CM) to produce high-performance thermoplastic composites reinforced with short carbon fibers. AM and CM techniques were integrated to control the fiber orientation (microstructure) and to reduce void content for the improved mechanical performance of the composite. The new integrated manufacturing technique is termed “additive manufacturing-compression molding” (AM-CM). For the present study, the most common materials were used for large-scale printing, i.e., acrylonitrile butadiene styrene (ABS), carbon fiber (CF)–filled ABS (CF/ABS) and glass fiber (GF)–filled ABS (GF/ABS). Three different manufacturing processes; (a) AM (b) extrusion compression molding (ECM), and (c) AM-CM were used to prepare four different panel configurations: (1) neat ABS, (2) CF/ABS, (3) overmold (CF/ABS over neat ABS), and (4) sandwich (neat ABS between two CF/ABS layers). The mechanical properties (tensile and flexural strength and modulus, and Izod impact energy) of samples prepared via all three manufacturing processes were compared. X-ray microcomputer tomography was employed to evaluate the fiber orientation distribution and the volumetric porosity content. The preform maintained high fiber alignment (≈ 82% of fibers within the range of 0–20° in the deposition direction), and the volumetric porosity was reduced by 50% from 3.79% to 1.91% after compression. The alignment of long pores along the deposition direction was also observed. The mechanical properties are discussed with correlation to the fiber alignment and void content in the samples. CF/ABS samples prepared by AM-CM showed significant improvement of 11.15%, 35.27%, 28.6%, and 74.3% in the tensile strength, tensile modulus, flexural strength, and flexural modulus, respectively, when compared with samples prepared by ECM. Unique aspects of this study are the demonstration of large-scale multimaterial AM and the use of multimaterials as preforms to make high-performance composites.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Mechanical behavior of carbonated MgO-based Engineered Cementitious Composite (ECC) after high temperatures exposure

Carbonated MgO-based Engineered Cementitious Composite (ECC) has ultrahigh tensile ductility and tight crack width control behavior. However, the expectation of improved fire-resistant has not been confirmed. This study explored the alterations to mechanical and microstructure characteristics of this material after exposure to temperatures up to 500 °C. Material mass loss, compressive strength, tensile strength, strain capacity, and matrix fracture toughness were measured. Scanning electron microscopy, mercury intrusion porosimetry, thermogravimetric analysis, and X-ray diffraction were used to probe the degradation of the cement matrix and fibers. The effect of elevated temperature on carbonated MgO-based ECC was further assessed via examination of the micromechanical behavior of the fiber-matrix. The objective of this research was to assess the performance of carbonated MgO-based ECC exposed to fire hazards. The tensile ductility of carbonated MgO-based ECC was found to be enhanced when exposed to ~100 °C as compared with those at room temperature ~20 °C. Further increase in exposure temperature, however, posed a negative impact on the composite compressive strength, ultimate tensile strength, and ability to control crack width. Here the results provide a useful database for further investigations into carbonated MgO-based ECC for fire safety enhancement.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Calculation of reinforced-concrete frame strength under a simultaneous static cross section load and a column lateral impact

When designing buildings with reinforced concrete that are planned to resist dynamic loads it is necessary to calculate this structural behavior under operational static and emergency impact and blast loads. Calculations of the structures under shock-wave loads can be performed by solving dynamic equations that do not consider static loads. Due to this fact the calculation of reinforced concrete frame under a simultaneous static and dynamic load in full 3d settings becomes a very non trivial and resource consuming problem. This problem can be split into two tasks. The first one is a shock-wave problem that can be solved using software package RANET-3, which allows solving the problem using finite elements method adapted for dynamic task. This method calculates strain-stress state of the material and its dynamic destruction, which is considered as growth and consolidation of micro defects under loading. On the second step the results of the first step are taken as input parameters for quasi static calculation of simultaneous static and dynamic load using finite elements method in AMP Civil Engineering-11.

36 MATERIALS SCIENCE↗
NASA NTRS2023

The Impact of ENSO and NAO Initial Conditions and Anomalies on the Modeled Response to Pinatubo-Sized Volcanic Forcing

Strong, strato-volcanic eruptions are a substantial, intermittent source of natural climate variability. Initial atmospheric and oceanic conditions, such as El Niño Southern Oscillation (ENSO) and the North Atlantic Oscillation (NAO), also naturally impact climate on interannual timescales. We examine how initial conditions of ENSO and NAO contribute to the evolution of climate in the period following a Pinatubo-type eruption using a large (81-member) ensemble of model simulations in GISS model E2.1-G. Simulations are initialized from sampled conditions of ENSO and NAO using the protocol of the coordinated CMIP6 Volcanic Model Intercomparison Project (VolMIP) – where aerosols are forced with respect to time, latitude, and height. We analyze paired anomalous variations (perturbed – control) to understand changes in global and regional climate responses under positive, negative, and neutral ENSO and NAO conditions. In particular, we find that for paired anomalies there is a high probability of strong (∼1.5 °C) warming of northern Eurasia surface air temperature in the first winter after the volcanic eruption for negative NAO ensembles coincident with decreased lower stratospheric temperature at the poles, decreased geopotential height, and strengthening of the stratospheric polar vortex. Climate anomalies (relative to average conditions across the control period), however, show no mean warming and suggest that the strength of this response is impacted by conditions present in the selected period of the control run. Again using paired anomalies, we also observe that under both +ENSO and −ENSO ensembles sea surface temperature decreases in the first post-eruptive boreal winter coinciding with surface cooling from volcanic aerosols. Neutral ENSO ensembles, on the other hand, show variability in their response with no clear trend in post-eruptive warming or cooling. In general, paired anomalies from unperturbed simulations give insight into the evolution of the climate response to volcanic forcing; however, when compared with anomalies from climatological conditions, it is clear that paired anomalies are significantly affected by sampled initial conditions occurring at the time of the volcanic eruption.

volcanic eruptions↗
NASA NTRS2022

A Quantitative Damage Tolerance Comparison of High Strength and High Modulus Carbon Fiber Sandwich Structure

This study presents experimental results of the compression after impact (CAI) testing of sandwich structure with face sheets made either with IM7/8552 high strength fiber or HM63/8552 high modulus fiber. While the HM63/8552 face sheet sandwich specimens would not be as damage tolerant as the IM7/8552 face sheet sandwich specimens, a quantitative measure of how much more damage tolerant the IM7/8552 face sheets were than the HM63/8552 face sheets was sought. Due to the IM7/8552 face sheets being 28% thicker than the HM63/8552 face sheets, the impact energies used needed to be adjusted for a fair comparison. The results show that the modulus is 35% lower for the IM7/8552 face sheet sandwich structure while the CAI strength

High modulus carbon fiber↗
DOE OSTI2024

Influence of Rare Earth Ce Additions on Microstructure and Mechanical Properties of Experimental Pipeline Steels

Herein, the effect of Ce additions ranging from 57 to 263 ppm is evaluated for an experimental pipeline steel. Compared to the Ce-free steel, progressive Ce additions result in a slightly refined microstructure, significantly improve transverse impact properties, and slightly increase strength. All these observations can be attributed to the gradual transformation of Mn sulfide and Mn–Si–Al oxide inclusions to Ce-containing oxide/sulfides. In particular, the inclusions consist exclusively of sub-5 μm spherical Ce 2 O 2 S particles upon near-stoichiometric additions of Ce, considering the oxygen and sulfur impurity level of the steel. In conclusion, the results suggest that Ce is a potentially promising alloying addition for next-generation pipeline steels by replacing overtly deleterious inclusions with potentially beneficial ones.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication and Characterization of Poly(lactic acid) Biocomposites Reinforced by Calcium Sulfate Whisker

The biodegradable poly(lactic acid) (PLA) composites filled with calcium sulfate whisker (CSW) were fabricated via melt-blending and subsequent injection molding. Surface organification of γ-aminopropyltriethoxysilane (APTES) on CSW was applied to accelerate the wettability of PLA to CSW. The mechanical properties, morphological structures, crystallization behaviors and thermal stabilities of PLA/CSW composites were investigated in detail. Results showed that modification of APTES changed the surface morphologies and element compositions, helping to form the well bonded interfaces. By adding CSW, the elastic modulus of PLA/CSW composites presented a sustained increment, while tensile strength, elongation at break and impact toughness were increased first and then decreased. The presence of CSW impeded the melt-crystallization but accelerated the cold-crystallization process. On the whole, the actual crystallinity for the composites was suppressed except for the case with 20% CSW. The thermal stability was enhanced by CSW as expected, and all the samples showed the exact same reaction order (n = 1) according to Carrasco method. Nevertheless, the activation energies were declined, indicating CSW was in favor of thermal decomposition of PLA phases. Finally, it was interestingly found that CSW could improve the comprehensive properties of PLA without deteriorating the processibility.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Resolving metal binding properties within subunits of a multimeric enzyme Mnx by surface induced dissociation and native ion mobility mass spectrometry

Multi-subunit enzymes function as coordinated assemblies. Yet most enzymatic assays measure the summed output of all populations in solution and cannot easily differentiate contributions of individual subunits. Native mass spectrometry detects intact protein complexes in the gas phase. Surface induced dissociation further releases subunits from protein complexes while retaining compact conformations and bound ligands. Combined with ion mobility, the released subunits can then be carefully monitored for more in-depth structural analysis. Mnx is a unique bacterial multicopper oxidase complex that oxidizes Mn(II) to form MnO 2 minerals, and is composed of three subunits: MnxG, a multicopper oxidase containing the active site, and two accessory proteins, MnxE and MnxF which also bind copper ions. Other known multicopper oxidases do not require accessory proteins, therefore the functions of MnxE and MnxF are not well understood. Here, we use native mass spectrometry with surface induced dissociation and ion mobility to characterize the metal binding properties of Mnx with two metals, catalytic Cu(II) and Mn(II) substrate. We demonstrate our assay can detect subtle structural changes within each subunit, which are presumably related to the allosteric mechanism. We also noticed that ionic strength and solution composition can impact metal binding and must be carefully investigated for such experiments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Statistically informed upscaling of damage evolution in brittle materials

The presence and growth of micro-cracks degrade the strength of brittle solids, greatly impacting the overall material response. Hence, the evolution of these micro-cracks must be accounted for in models describing the relationship between stress and strain so that accurate predictions of material failure can be made. The evolution of individual cracks and crack networks can be simulated with high-fidelity microscale models utilizing highly resolved meshes that can be computationally expensive to a point in which it limits the simulation scale. Hence, for many engineering applications that require simulations of large components, continuum-scale models, which cannot explicitly resolve individual cracks and thus lose important physical information, are required. In this work, we bridge these two scales by developing and implementing a continuum-scale effective moduli constitutive model that is informed by crack statistics generated from a high-fidelity model resolved using a finite-discrete element method (FDEM) implementation. Using statistical information describing the evolution of crack lengths and orientations, this model can capture the effects of brittle damage evolution without the need to resolve individual cracks. We have successfully captured the stress-strain behavior of the high-fidelity simulations using the statistics-based constitutive model shown through direct comparison of stress-strain curves. The curves match within error bars present in the strain-softening portions of the stress-strain curve of the high-fidelity results due to the statistical variation of the initial pre-existing crack network. In conclusion, the stress-strain curves are also compared to experimental results for similar loading conditions and show good qualitative agreement.

36 MATERIALS SCIENCE↗