Search NASA⌕ Search

SEARCH · Search NASA

Results for “Fracture toughness”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 595 records · Page 33

Flaw-insensitive fracture of a micrometer-sized brittle metallic glass

Brittle materials, such as oxide glasses, are usually very sensitive to flaws, giving rise to a macroscopic fracture strength that is much lower than that predicted by theory. The same applies to metallic glasses (MGs), with the important difference that these glasses can exhibit certain plastic strain prior to catastrophic failure. Here we consider the strongest metallic alloy known, a ternary Co 55 Ta10B 35 MG. In this work, we show that this macroscopically brittle glass is flaw-insensitive at the micrometer scale. This discovery emerges when testing pre-cracked specimens with self-similar geometries, where the fracture stress does not decrease with increasing pre-crack size. The fracture toughness of this ultra-strong glassy alloy is further shown to increase with increasing sample size. Both these findings deviate from our classical understanding of fracture mechanics, and are attributed to a transition from toughness-controlled to strength-controlled fracture below a critical sample size.

36 MATERIALS SCIENCE↗

Controlling substrate temperature with infrared heating to improve mechanical properties of large-scale printed parts

Additively manufactured parts made with polymer extrusion techniques can be 50-75% weaker in the z-direction (across layers) than in the x- and y-directions. This has been attributed to poor mobility of polymer chains and a low degree of entanglement across a cold deposition interface. This is particularly a challenge when printing large-scale parts, such as with the Big Area Additive Manufacturing (BAAM) system, because layer times can exceed several minutes. The current work presents a method for controlling the temperature of the substrate material on the BAAM just prior to deposition using infrared heating lamps. Additionally, long layer times were simulated by actively cooling the material following deposition of each layer. The effect of substrate temperature on the z-direction mechanical properties of 20% carbon fiber reinforced acrylonitrile butadiene styrene (ABS) was measured for an initial temperature ranging from 50 °C to 150 °C and a preheated temperature ranging from 150 °C to 220 °C. Infrared preheating proved to be very effective when applied to substrates that had cooled considerably, almost doubling the tensile strength and increasing the fracture toughness by a factor of 7x.

36 MATERIALS SCIENCE↗

Interlayer fusion bonding of semi-crystalline polymer composites in extrusion deposition additive manufacturing

This work focuses on the evolution of interlayer fracture toughness properties of fiber-reinforced, semi-crystalline polymers in the extrusion deposition additive manufacturing (EDAM) process. Further, this work bridges the gap between the additive process conditions (time-temperature history) and the effective layer-to-layer fracture properties developed within a printed component. This is the first step to predict delamination that can occur during printing, during cooling to room temperature after printing, and during service performance of an additively manufactured geometry. A phenomenological model is developed for fusion bonding of semi-crystalline polymer matrix composites by coupling the interdiffusion of polymer chains with the evolution of polymer crystallinity. While the interdiffusion is captured by reptation theory of polymer dynamics, the evolution of crystallinity is modeled by phenomenological crystallization kinetics and crystal melting dynamics. Further, a methodology is developed to determine the critical strain energy release rate, G IC of the interlayer interface and experiments are conducted utilizing the double cantilever beam fracture test geometry. In conclusion, predictions of GIC as a function of thermal history are compared with experiments.

36 MATERIALS SCIENCE↗

Impacts of irregularly-distributed acidified brine flow on geo-chemo-mechanical alteration in an artificial shale fracture under differential stress

The efficacy of geological carbon sequestration is reliant on the integrity of the caprock and its resistance to physical and chemical alteration. Caprocks with high abundance of reactive carbonates like calcite are susceptible to acid-promoted dissolution and can result in structural weakening. This work investigates the effect of acidified brine flow through an artificially fractured, high-carbonate (30 % by XRD) shale under differential compressive stress. Cylindrical samples were cut in half vertically and milled to create an artificial fracture with interlocking asperities and open channels. Samples were sheared with a single applied stress in a custom flow cell housed within an industrial CT scanner. Further, either acidic (pH 4) or reservoir-simulated (pH 9.5) brine was flowed through the artificial fracture for 7–8 days under reservoir pressure and room temperature. Model simulations indicate flow mainly occurred in open channels, with limited flow between overlapping asperities. Analysis of fracture surfaces by optical and scanning electron microscopy show increased surface alteration and roughness after exposure to pH 4 versus pH 9.5 brine indicating mineral dissolution/loss, and this effect is greater in areas that receive the highest brine flows. Similarly, surface analysis by scratch testing shows fracture toughness decreases more after exposure to acidic versus reservoir-simulated brine, with the greatest alteration in areas of highest acidic brine flows. Despite weakening, no shear slip occurred. Overall, the results indicate that acidified brine can result in significant physical and geomechanical alteration of irregular fracture surfaces in shale caprock, with greatest effects in preferential flow regions.

58 GEOSCIENCES↗

A Review of the Proposed K (sub Isi) Offset-Secant Method for Size-Independent Linear-Elastic Toughness Evaluation

The proposed size-independent linear-elastic fracture toughness, K (sub Isi), for potential inclusion in ASTM E399 targets a consistent 0.5 millimeters crack extension for all specimen sizes through an offset secant that is a function of the specimen ligament length. The K (sub Isi) method also includes an increase in allowable deformation, and the removal of the P (sub max)/P (sub Q) criterion. A finite element study of the K (sub Isi) test method confirms the viability of the increased deformation limit, but has also revealed a few areas of concern. Findings: 1. The deformation limit, b (sub o) greater than or equal to 1.1 times (K (sub I) divided by delta (sub ys) squared) maintains a K-dominant crack tip field with limited plastic contribution to the fracture energy; 2. The three dimensional effects on compliance and the shape of the force versus CMOD (Crack-Mouth Opening Displacement) trace are significant compared to a plane strain assumption; 3. The non-linearity in the force versus CMOD trace at deformations higher than the current limit of 2.5 times (K (sub I) divided by delta (sub ys) squared) is sufficient to introduce error or even "false calls" regarding crack extension when using a constant offset secant line. This issue is more significant for specimens with W (width) greater than or equal to 2 inches; 4. A non-linear plasticity correction factor in the offset secant may improve the viability of the method at deformations between 2.5 times (K (sub I) divided by delta (sub ys) squared) and 1.1 times (K (sub I) divided by delta (sub ys) squared).

James, Mark↗

Synthesis of high-entropy carbides from multi-metal polymer precursors

Three compositions of high-entropy carbides, (TiHfVNbTa)C, (TiZrHfNbTa)C and (TiZrNbTaW)C were synthesized via a modified Pechini process, in which citric acid served as both a cation chelating agent and a carbon source. Through pyrolysis and spark plasma sintering, single phase high-entropy carbides were formed from the homogeneous precursors at a relatively low temperature of 1800 °C. The dispersion of cations in the polymer precursor facilitated shorter diffusion distances in polymer-derived materials, and thus compositional homogeneity was significantly improved relative to materials produced by a solid-state method, as quantified by a defined coefficient of variation applied to energy-dispersive X-ray spectroscopy. Finally, a finer microstructure in polymer-derived materials results in improved fracture toughness with a K IC value of 4.29 MPa·m 1/2 achieved for (TiHfVNbTa)C.

36 MATERIALS SCIENCE↗

Material Characterization-Based Wear Mechanism Investigation for Biomass Hammer Mills

Biomass, as harvested, is composed of inorganic compounds both intrinsically and extrinsically and can be abrasive. The present study investigates the wear modes and mechanisms of two types of blades of hammer mills used in biomass size reduction (impacting the particle size and distribution) and densification (impacting the size, shape, and density). The dominant wear modes for the stage 1 steel blades are determined to be erosive and polishing wear. For the stage 2 blades with a carbide weld overlay, the main wear mechanisms are erosion and fracture. Partial replacement of Co by Fe in the outer layer of the carbide grits, likely induced by diffusion during high-temperature welding, has been correlated to the observed microcracking. Finally, the microcracking is believed to weaken the grit strength and fracture toughness to make the overlay prone to fracture and erosion due to repetitive contact with the inorganic contents in chopping biomass.

42 ENGINEERING↗

Mechanistic Study of Delamination Fracture in Al-Li Alloy C458 (2099)

Delamination fracture has limited the use of lightweight Al-Li alloys. In the present study, electron backscattered diffraction (EBSD) methods were used to characterize crack paths in Al-Li alloy C458 (2099). Secondary delamination cracks in fracture toughness samples showed a pronounced tendency for fracture between grain variants of the same deformation texture component. These results were analyzed by EBSD mapping methods and simulated with finite element analyses. Simulation procedures include a description of material anisotropy, local grain orientations, and fracture utilizing crystal plasticity and cohesive zone elements. Taylor factors computed for each grain orientation subjected to normal and shear stresses indicated that grain pairs with the largest Taylor factor differences were adjacent to boundaries that failed by delamination. Examination of matching delamination fracture surface pairs revealed pronounced slip bands in only one of the grains bordering the delamination. These results, along with EBSD studies, plasticity simulations, and Auger electron spectroscopy observations support a hypothesis that delamination fracture occurs due to poor slip accommodation along boundaries between grains with greatly differing plastic response.

Tayon, W. A.↗

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↗

Development of Low-Cost, Crack-Tolerant Metallization Using Screen Printing

One of the ways to reduce the cost of solar electricity to 3/kWh, thus reaching parity with fossil-fuel-based generation, is to reduce the degradation rate of solar modules and extend their lifetime well beyond 30 years. The extended module lifetime in turn can positively influence the financial model and the bankability of utility-scale PV projects. Today, the highest-riskpriority solar module degradation mechanism is what is known as hot spots, often induced by cell cracks. In order to address this degradation mechanism, we make use of low-cost, multi-walled carbon nanotubes embedded in commercial screen-printable silver pastes. When the carbon nanotubes are properly functionalized and appropriately incorporated into commercial silver pastes, the resulting metal contacts on solar cells, after screen-printing and firing, show exceptional fracture toughness. These composite metal contacts possess increased ductility, electrical gap-bridging capability up to 50 um, and 'self-healing' to regain electrical continuity even after cycles of complete electrical failure under extreme strain.

14 SOLAR ENERGY↗

Varied enhancements in mechanical properties and sodium compatibility of Grade 92 by thermomechanical treatments

As a candidate material for advanced nuclear reactors, a ferritic-martensitic (FM) steel Grade 92 in the standard normalized and tempered (NT) condition was subjected to two types of thermomechanical treatments (TMTs) with one having a lower level of deformation (T5A) and the other having a higher level of deformation (T5B). The testing results of the three conditions indicated that the TMTs significantly improved yield strength, creep resistance, fracture toughness, and sodium corrosion resistance compared with the NT condition. T5A excelled at creep resistance while T5B at sodium corrosion resistance. Microstructural characterization of the three conditions supports the varied enhancements in the properties. This study suggests that an appropriate TMT can be developed and applied to FM steels to better meet specific application requirements.

36 MATERIALS SCIENCE↗

3Y-TZP Toughened and Oxidation-resistant U 3 Si 2 Composites for Accident Tolerant Fuels

In this work, we report an innovative approach synergizing multiple effects of microstructure control, oxide protection and phase transformation-induced mechanically toughening to develop advanced U 3 Si 2 fuels with state-of-the-art materials properties. 3Y-TZP (3 mol% yttria doped stabilized tetragonal zirconia) additives are incorporated and uniformly distributed into the SPS-densified U 3 Si 2 fuel matrix, enhancing materials fracture toughness up to 4.04 MPa m 1/2 . The 3Y-TZP incorporated U 3 Si 2 composite pellets show significantly improved onset temperature of oxidation above 560 °C, which can be further improved to 617 °C with 3 vol% addition by post-sintering thermal annealing. We report the development of mechanically tough and oxidation-resistant U 3 Si 2 with minimal additive represents a major step forward towards realizing the potential of high density U 3 Si 2 as the leading fuel concept to increase accidence tolerance of nuclear energy systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Crack Growth Testing of an Aluminum Oxynitride (AlON) for International Space Station Kick Panes

The mechanical properties of an aluminum oxynitride supplied as ground beams and disks were measured using ASTM International (formerly American Society for Testing and Materials) standard test methods. The slow crack growth tests were complicated by a "short" finish that increased strength scatter. Refining of the finish by more material removal in the second stage of grinding or the use of uniaxial grinding as specified in ASTM C1499 might have avoided the issue. The structural design parameters are an elastic modulus of E = 319 GPa, Poisson's ratio of v = 0.26, a fracture toughness of KIvb(A) = 2.18 MPa/m, slow crack growth (SCG) parameter n = 36, and SCG parameter A = 1.96 x 10-11 m/s.(MPa/m)n. For a ground finish, the Weibull parameters are a mean modulus of m = 14.0 and characteristic strength of sigma theta = 250.2 MPa. The 2015 vintage material exhibits similar mechanical properties to a 2010 vintage billet. Indentation flaws were not sensitive to the inherent crack growth mechanisms of this material and produced misleading results.

strength↗

Through-thickness fracture behavior of neutron-irradiated nuclear graphite NBG-17 Using X-ray micro-CT

Achieving precise control over crack propagation in nuclear graphite and conducting quantitative analysis remain challenging. In this study, the through-thickness fracture behavior of pristine and neutron-irradiated (700 °C, ∼7 dpa) NBG-17 nuclear graphite was investigated using split-disc testing coupled with micro-computed tomography (micro-CT). A notably lower number of micropores was observed in the neutron-irradiated specimen. The fracture toughness of neutron-irradiated NBG-17 was measured to be 1.45 MPa√m, compared to 1.17 ± 0.05 MPa√m for the pristine specimen. In both materials, cracks were found to initiate at the filler–binder interface, and often correlated with microstructural features such as pores and thermal cracks. Crack bridging and deflections emerged as the primary toughening mechanisms in both unirradiated and irradiated NBG-17. However, compared with the pristine specimen, the cracks in the neutron-irradiated specimen were more likely to grow trans granularly, resulting in less deflected crack paths. The reduced micro-porosity and strengthened filler–binder boundaries were considered to be the cause of the observed differences in crack morphologies. In conclusion, this study provides a qualitative analysis of the fracture behavior of neutron-irradiated nuclear graphite in the absence of radiolytic oxidation.

36 - MATERIALS SCIENCE↗

Assessment of critical flaw sizes and crack driving forces during additive manufacturing of metallic materials

Additive manufacturing (AM) of complex engineering components is often plagued by a high susceptibility to cracking, particularly in high-strength metallic materials. While alloy design efforts have made progress in mitigating solidification defects, there remains a need for mechanistic guidelines to predict susceptibility to solid-state cracking. To address this gap, driving forces for the growth of melt pool cracks are calculated across a wide range of alloys using an efficient computational framework. Calculations are coupled with rapid single track laser experiments to elucidate trends in cracking from laser melting. The analyses conducted here highlight the important role of material properties in susceptibility to cracking, notably fracture toughness and elastic modulus. An important finding is that residual stresses that are limited in magnitude to the yield stress of the material are likely insufficient to drive cracking during cooling. Furthermore, the implications of these results are discussed in the context of alloy design for AM and residual stress accumulation during AM.

36 MATERIALS SCIENCE↗

Fracture behavior of irradiation induced nanocrystalline UO 2 studied by in-situ mechanical testing in transmission electron microscopy

Uranium Dioxide (UO 2 ) is widely used as a fuel in current light water reactors (LWRs). Upon accumulation of radiation damage, LWR UO 2 fuel pellets start to develop a different microstructure at the pellet periphery when fuel burnup exceeds 45–50 GWd/tHM. The resulting porous, nanocrystalline microstructure is one of the most prominent microstructural changes occurring in such fuel. Its fracture mechanisms, which causes fuel fine fragmentation, could impact safety limits when the cladding breaches. Direct measurements of these properties are challenging, therefore a surrogate obtained via ion irradiation can be used. In this study, multiple microcantilevers were fabricated by focused ion beam from both fresh UO 2 and UO 2 irradiated with 84 MeV Xe 26+ ions to a peak dose of 1357 displacements per atom (dpa). Further, the irradiation produced a pseudo high burnup structure approximately 2 µm below the surface. In-situ nano-mechanical bending tests were conducted to investigate the fracture behavior and the effect of the surrogate UO 2 high burnup structure on local fracture properties. Fresh UO 2 fuel was observed to fracture in transgranular mode without nucleation or movement of dislocations. However, the Xe-irradiated nanocrystalline microcantilevers fractured along the grain boundaries, with no influence from the pre-existing micro-cracks in the microcantilever. Fracture toughness for this type of surrogate high burnup UO 2 structure is reported for the first time in literature. Both the fracture stress and toughness show degradation for UO 2 as a result of Xe-irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗