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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Sensitivity of Simulations of Double-detonation Type Ia Supernovae to Integration Methodology

Abstract We study the coupling of hydrodynamics and reactions in simulations of the double-detonation model for Type Ia supernovae. When assessing the convergence of simulations, the focus is usually on spatial resolution; however, the method of coupling the physics together as well as the tolerances used in integrating a reaction network also play an important role. In this paper, we explore how the choices made in both coupling and integrating the reaction portion of a simulation (operator/Strang splitting versus the simplified spectral deferred corrections method we introduced previously) influences the accuracy, efficiency, and nucleosynthesis of simulations of double detonations. We find no need to limit reaction rates or reduce the simulation time step to the reaction timescale. The entire simulation methodology used here is GPU-accelerated and made freely available as part of the Castro simulation code.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Imaging systematics induced by galaxy subsample fluctuation: New systematics at second order

Imaging systematics refers to the inhomogeneous distribution of a galaxy sample caused by varying observing conditions and astrophysical foregrounds. Current mitigation methods correct the galaxy density fluctuations $n$ gal /$\bar{n}$ gal caused by imaging systematics assuming that all galaxies in a sample have the same $n$ gal /$\bar{n}$ gal . Under this assumption, the corrected sample cannot perfectly recover the true correlation function. Here, we name this effect subsample systematics. For a galaxy sample, even if its overall sample statistics [redshift distribution 𝑛⁡(𝑧), galaxy bias 𝑏⁡(𝑧)], are accurately measured, 𝑛⁡(𝑧), 𝑏⁡(𝑧) can still vary across the observed footprint. It makes the correlation function amplitude of galaxy clustering higher, while correlation functions for galaxy-galaxy lensing and cosmic shear do not have noticeable change. Such a combination could potentially degenerate with physical signals on small angular scales, such as the amplitude of galaxy clustering, the impact of neutrino mass on the matter power spectrum, etc. subsample systematics cannot be corrected using imaging systematics mitigation approaches that rely on the cross-correlation signal between imaging systematics maps and the observed galaxy density field. In this paper, we derive formulated expressions of subsample systematics, demonstrating its fundamental difference with other imaging systematics. We also provide several toy models to visualize this effect. Finally, we discuss a potential method to estimate and mitigate subsample systematics by forward modeling its behavior using synthetic source injection.

Kong, Hui [The Barcelona Institute of Science and ↗
DOE OSTI2021

Learning to Correct Climate Projection Biases

The fidelity of climate projections is often undermined by biases in climate models due to their simplification or misrepresentation of unresolved climate processes. While various bias correction methods have been developed to post-process model outputs to match observations, existing approaches usually focus on limited, low-order statistics, or break either the spatiotemporal consistency of the target variable, or its dependency upon model resolved dynamics. We develop a Regularized Adversarial Domain Adaptation (RADA) methodology to overcome these deficiencies, and enhance efficient identification and correction of climate model biases. Instead of pre-assuming the spatiotemporal characteristics of model biases, we apply discriminative neural networks to distinguish historical climate simulation samples and observation samples. The evidences based on which the discriminative neural networks make distinctions are applied to train the domain adaptation neural networks to bias correct climate simulations. We regularize the domain adaptation neural networks using cycle-consistent statistical and dynamical constraints. An application to daily precipitation projection over the contiguous United States shows that our methodology can correct all the considered moments of daily precipitation at approximately $1^\circ$ resolution, ensures spatiotemporal consistency and inter-field correlations, and can discriminate between different dynamical conditions. Our methodology offers a powerful tool for disentangling model parameterization biases from their interactions with the chaotic evolution of climate dynamics, opening a novel avenue toward big-data enhanced climate predictions.

58 GEOSCIENCES↗
DOE OSTI2023

Simulations and analysis tools for charge-exchange (d, 2 He) reactions in inverse kinematics with the AT-TPC

Charge-exchange (d, 2 He) reactions in inverse kinematics at intermediate energies are a very promising method to investigate the Gamow–Teller transition strength in unstable nuclei. A simulation and analysis software based on the attpcroot package was developed to study this type of reactions with the active-target time projection chamber (AT-TPC). The simulation routines provide a realistic detector response that can be used to understand and benchmark experimental data. Analysis tools and correction routines can be developed and tested from simulations in ATTPCROOT , because they are processed in the same way as the real data. In particular, we study the feasibility of using coincidences with beam-like particles to unambiguously identify the (d, 2 He) reaction channel, and to develop a kinematic fitting routine for future applications. More technically, the impact of space-charge effects in the track reconstruction, and a possible correction method are investigated in detail. Finally, this analysis and simulation package constitutes an essential part of the software development for the fast-beams program with the AT-TPC.

(d,2He)↗
DOE OSTI2023

Multigrid Reduction in Time for Chaotic and Hyperbolic Problems (Final Report)

The coming massive parallelism of exascale computing presents a pressing challenge for the many DOE simulations of time-dependent partial differential equations (PDEs), which typically use traditional sequential time stepping methods. Since this traditional approach is inherently serial, it presents a sequential bottleneck when moving to exascale computing, because future performance gains will come through greater concurrency, not faster clock speeds. Thus, the goal of this work is to research parallelism in time, i.e., methods that compute multiple time values simultaneously, not sequentially. The focus will be on hyperbolic and chaotic problems of interest to DOE, with the goal of enabling scalable simulations of time-dependent hyperbolic and chaotic problems on future architectures. The chosen methodology for solving these problems parallel-in-time is multigrid, because multigrid (when it works) is a powerful, optimal, and scalable solver for discretized PDEs. Multigrid is already commonly used in many DOE simulations for scalably and optimally solving space-only PDE problems. The areas of hyperbolic and chaotic problems are chosen because of their relevance to problems of programmatic interest to DOE. However, these problems are also well-known to be difficult for parallelin-time methods, with the most common method, parareal, diverging in many cases. The current state-of-the-art for parallel-in-time at LLNL is the multigrid reduction in time (MGRIT) XBraid package, which also struggles for such problems, while still showing some improvement over parareal. In summary, new methods are needed for an efficient parallel-in-time scheme for hyperbolic and chaotic problems, and this work shall research promising new multigrid methods in this area. In particular, this work shall continue researching the directions from the current collaboration with Dr. Falgout, which are laid out in the work Toward Parallel in Time for Chaotic Dynamical Systems and showed the first known results of a parallel-in-time speedup for a chaotic problem. This work outlines two key improvements to XBraid for chaotic problems, the so-called “theta” and “delta-correction” methods. Here, these two improvements will be implemented in a high-performance but general way in XBraid and explored for more complicated problems. We will additionally research, as time allows, improvements to these techniques, as well as multigrid relaxation techniques based on Least Squares Shadowing (LSS by Wang) and a nonintrusive block tridiagonal solver based on MGRIT, called TriMGRIT.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Multigrid Reduction in Time for Chaotic and Hyperbolic Problems (Final Report)

The coming massive parallelism of exascale computing presents a pressing challenge for the many DOE simulations of time-dependent partial differential equations (PDEs), which typically use traditional sequential time stepping methods. Since this traditional approach is inherently serial, it presents a sequential bottleneck when moving to exascale computing, because future performance gains will come through greater concurrency, not faster clock speeds. Thus, the goal of this work is to research parallelism in time, i.e., methods that compute multiple time values simultaneously, not sequentially. The focus will be on hyperbolic and chaotic problems of interest to DOE, with the goal of enabling scalable simulations of time-dependent hyperbolic and chaotic problems on future architectures. The chosen methodology for solving these problems parallel-in-time is multigrid, because multigrid (when it works) is a powerful, optimal, and scalable solver for discretized PDEs. Multigrid is already commonly used in many DOE simulations for scalably and optimally solving space-only PDE problems. The areas of hyperbolic and chaotic problems are chosen because of their relevance to problems of programmatic interest to DOE. However, these problems are also well-known to be difficult for parallel-in-time methods, with the most common method, parareal, diverging in many cases. The current state of-the-art for parallel-in-time at LLNL is the multigrid reduction in time (MGRIT) XBraid package, which also struggles for such problems, while still showing some improvement over parareal. In summary, new methods are needed for an efficient parallel-in-time scheme for hyperbolic and chaotic problems, and this work shall research promising new multigrid methods in this area. In particular, this work shall continue researching the directions from the current collaboration with Dr. Falgout, which are laid out in the work Toward Parallel in Time for Chaotic Dynamical Systems and showed the first known results of a parallel-in-time speedup for a chaotic problem. This work outlines two key improvements to XBraid for chaotic problems, the so-called “theta” and “delta-correction” methods. Here, these two improvements will be further researched and improved (including with a new relaxation method inspired by on Least Squares Shadowing (LSS)) and explored for more complicated problems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Preliminary results of the 2023 International Fermilab Booster Studies

Here, an overview is given of the methods and preliminary results from dedicated beam studies on three topics conducted over five days in July 2023. In the first study, the Fermilab Booster magnets were held constant at magnetic fields corresponding to the injection energy. The beam loss and emittance growth were observed under varying intensity, tunes, and sextupole resonances. The corresponding beam conditions were also simulated with the MADX-SC code [1]. In the second study, measurements of the vertical half-integer resonance and correction methods are conducted for high-intensity beams ramping in the Booster. Finally, syncho-betatron instabilities are observed during transition-crossing in the Booster under strong space-charge conditions.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

An Inverse Heat Conduction Algorithm Used to Calculate the Temperatures on the Inner and Outer Cylindrical Surfaces of an HMX-based PBX Explosive Annulus

In this work, a new Inverse Heat Conduction (IHC) algorithm is applied to estimate the surface temperatures at twelve locations on the inner and outer cylindrical boundaries of an HMX-based Plastic Bonded Explosive (PBX) annulus. This IHC algorithm was developed in references using a set of Direct Heat Conduction (DHC) solutions and a temperature correction method. The DHC solutions were calculated using a Galerkin based finite element (FE) method. This HMX based PBX annulus was used in the Large Scale Annular Cookoff (LSAC) experiment, Shot 5. The reason Shot 5 was chosen as a prototype mathematical model for this study is that the temperature was measured at eighteen locations in the midplane of the HMX-based PBX annulus. In addition, this annulus underwent an experimental thermal ignition and a deflagration that caused a thermal explosion and the disassembly of the experiment. The objective of this study is to describe how the application of the temperature correction algorithm produced the convergence of the DHC solutions to the measured temperatures at twelve internal locations in the midplane of the HMX-based PBX annulus.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Self-interaction error overbinds water clusters but cancels in structural energy differences

Here, we gauge the importance of self-interaction errors in density functional approximations (DFAs) for the case of water clusters. To this end, we used the Fermi–Löwdin orbital self-interaction correction method (FLOSIC) to calculate the binding energy of clusters of up to eight water molecules. Three representative DFAs of the local, generalized gradient, and metageneralized gradient families [i.e., local density approximation (LDA), Perdew–Burke–Ernzerhof (PBE), and strongly constrained and appropriately normed (SCAN)] were used. We find that the overbinding of the water clusters in these approximations is not a density-driven error. We show that, while removing self-interaction error does not alter the energetic ordering of the different water isomers with respect to the uncorrected DFAs, the resulting binding energies are corrected toward accurate reference values from higher-level calculations. In particular, self-interaction–corrected SCAN not only retains the correct energetic ordering for water hexamers but also reduces the mean error in the hexamer binding energies to less than 14 meV/ H 2 O from about 42 meV/ H 2 O for SCAN. By decomposing the total binding energy into many-body components, we find that large errors in the two-body interaction in SCAN are significantly reduced by self-interaction corrections. Higher-order many-body errors are small in both SCAN and self-interaction–corrected SCAN. These findings suggest that orbital-by-orbital removal of self-interaction combined with a proper DFA can lead to improved descriptions of water complexes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

BISON Capabilities for LWR Fuel Behavior Analysis During Accident and High-burnup Conditions

The U.S. Department of Energy (DOE)'s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program aims to develop predictive capabilities using computational methods for the analysis and design of advanced reactor and fuel cycle systems. This program has been supporting the development of BISON which is a high-fidelity and high-resolution fuel performance tool at the engineering scale. Increasing recent interest in applications at extended burnups motivated this study to incorporate more physically based models in BISON. This document details integration of newly implemented modeling capabilities into BISON, which includes (1) new thermal conductivity models that are valid up to 100 GWd/t, (2) models for the formation of the high-burnup structure (HBS), (3) two porosity correction methods beingapplied on the thermal conductivity due to the conducting pores during the HBS formation. BISON's results are verified and validated to test the new modeling capabilities

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Intact archeological human bones and age at death studied with transmission x–ray diffraction and small angle x–ray scattering

In this work, high-energy, wide-angle x-ray scattering (WAXS, x-ray diffraction) and small-angle x-ray scattering (SAXS) were used to study intact human second metacarpal bones (mc2) from two UK archeological sites. A novel method correcting for irregular mass distribution was applied in these transmission geometry experiments done at beamline 1-ID of the Advanced Photon Source. The authors asked whether there were age-at-death-related changes in carbonated apatite (cAp) lattice parameters and whether SAXS could detect collagen D-period peaks in the archeological mc2. For each of the two sites, Ancaster and Wharram Percy in England, six female mc2s were studied; for each site, two were from each of three age-at-death cohorts (young, 18-29 years; middle, 30-49 years; old >= 50 years) along with a modern control mc2. The Rietveld method was applied to the WAXS patterns to provide precise lattice parameter values. The cAp lattice parameters did not correlate with age-at-death estimated from dental wear. From WAXS and the 00.2 diffraction peak widths, four archeological mc2s possessed coherently scattering domain lengths (crystallite c-axis sizes) that matched that of the modern mc2; SAXS revealed the same four archeological mc2 had D-period peak intensities equivalent to that of the modern mc2. The other eight archeological mc2s had significantly larger crystallite sizes (than the modern mc2) and weak or absent D-period peaks, differences attributed to diagenetic changes. Based on these data, the authors suggest that WAXS 00.2 peak width and SAXS D-period peak intensity can be used with intact bones to select those likely to retain largely unaltered tissue nanostructure, which might be required for other analyses. Taken as a whole, the results suggest detecting age-related deterioration in nanostructural features may be difficult in bone showing significant bioerosion.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Mechanics of the Ring Tension Test (RTT): A Finite Element-based Investigation

The ring tension test (RTT) is an experimental method for determining mechanical behavior in a material’s circumferential or hoop direction. It is a crucial test for testing anisotropic materials with tube geometry, such as nuclear fuel cladding or irradiated pipes. Several RTT configurations exist, each with their own advantages and disadvantages. However, this test is significantly more complex than traditional tensile testing and can be especially sensitive to small differences and inconsistencies in the test setup and geometry, ultimately affecting the derived mechanical properties. Previous research has focused on method development, and little work has been done on understanding the subtle differences between an ideal test and experiments, specifically when the tests are performed on highly irradiated materials in hot cells. In this work, a finite element-based investigation of the RTT is conducted. Two promising test configurations are investigated, comparing their ability to determine accurate material strengths through plastic deformation. Several non-ideal conditions and uncontrollable effects which are likely to occur during experimental testing such as machining tolerances, variations of specimen geometry from nominal dimensions, rotation of specimens and fixturing, and other test setup discrepancies are studied. The sensitivity of measured strengths to these conditions is presented. A mechanics-based approach to describing and correcting raw data to determine actual strengths is also included for one of the configurations, resulting in a robust correction method with highly accurate material strength measurements. Based on these analyses, the hemicylindrical mandrel configuration is recommended with a gauge region oriented at a 45° angle.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Evaluation of the ring tension test (RTT) for robust determination of material strengths

The ring tension test (RTT) is an experimental method for determining mechanical behavior in a material’s circumferential or hoop direction. It is a crucial test for testing anisotropic materials with tube geometry, such as nuclear fuel cladding or irradiated pipes. Several RTT configurations exist, each with their own advantages and disadvantages. However, this test is significantly more complex than traditional tensile testing and can be especially sensitive to small differences and inconsistencies in the test setup and geometry, ultimately affecting the derived mechanical properties. Previous research has focused on method development, and little work has been done on understanding the subtle differences between an ideal test and experiments, specifically when the tests are performed on highly irradiated materials in hot cells. In this work, a finite element-based investigation of the RTT is conducted to fill this gap. The two most used test configurations are investigated, comparing their ability to determine accurate material strengths through plastic deformation. Several non-ideal conditions and uncontrollable effects which are likely to occur during experimental testing such as machining tolerances, variations of specimen geometry from nominal dimensions, rotation of specimens and fixturing, and other test setup discrepancies are studied. The sensitivity of measured strengths to these conditions is presented. A mechanics-based approach to describing and correcting raw data to determine actual strengths is also included for one of the configurations, resulting in a robust correction method with highly accurate material strength measurements. Finally, based on these analyses, the hemicylindrical mandrel configuration is recommended with a gauge region oriented at a 45° angle.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Second-generation downscaled earth system model data using generative machine learning

The second-generation Sup3rCC dataset provides high-resolution meteorological data generated through the downscaling of multiple earth system models (ESMs) from the Coupled Model Intercomparison Project Phase 6 (CMIP6). This downscaling is performed through application of a generative machine learning approach called Super-Resolution for Renewable Resource Data (sup3r). This dataset builds on the first-generation Sup3rCC data by applying improved bias correction methods and adding downscaled precipitation to the output variables. As with the first Sup3rCC version, the data still include temperature, wind speed and direction at multiple heights, pressure, three components of downwelling solar radiation, and relative humidity—all at 4-kilometer (km) hourly resolution over the contiguous United States. This is a 25x spatial enhancement and 24x temporal enhancement of the source 100-km daily-average ESM data. This extension of the Sup3rCC dataset includes data from six ESMs from two shared socioeconomic pathways (SSPs) totaling 400 years of data with multiple future projections of changing meteorological conditions. The scenario selection was based on a structured evaluation of historical ESM skill and comprehensive representation of possible trajectories of future climate change in temperature, humidity, precipitation, solar irradiance, and near-surface wind speeds. The inclusion of multiple future projections is intended to enable users to assess key drivers of un 36 certainty and variability. All data are double-bias corrected, resulting in a product that can be used out-of-the-box for energy system analysis with minimal historical bias. The potential applications of Sup3rCC data extend to various topics in renewable energy resource assessment, energy systems modeling, and grid resilience studies. High-resolution future meteorological projections are critical for evaluating the effects of changing meteorological conditions on renewable energy generation, energy demand, and for optimizing energy storage and grid infrastructure. The 4-km hourly resolution of the downscaled data enables understanding of spatial and temporal variability at the scales necessary for energy system operational planning. In addition, the dataset can support risk assessments by providing detailed information on possible future extreme weather events and long-term meteorological variability at scales relevant to energy infrastructure. By offering an enhanced representation of possible future meteorological conditions, the second-generation Sup3rCC dataset enables more precise modeling of energy resilience and adaptation strategies in response to changing meteorological conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Initial study on cross section generation requirements for a PBR equilibrium core

A Serpent model of the HTR-PM equilibrium core was developed for use in cross section prepa-ration studies in order to guide methods development for the Griffin reactor multiphysics applica-tion. The model includes detailed isotopics for 10 distinct pebble burnup groups in 126 core zoneswith unique fuel and moderator temperatures obtained from a coupled neutronics-thermal-fluidsequilibrium core calculation using Griffin-Pronghorn. A sensitivity study of the fuel and mod-erator temperatures for various core regions was performed with the MOOSE stochastic tools.The results show that the uncertainties are, not unexpectedly, dominated by the value of the fluidtemperature and that the power level, heat transfer coefficient and effective conduction to neigh-boring pebbles and fluid constitute, at best, second order effects. The temperature uncertaintyrange varies from 28 K to 57 K at the core entry and exit planes, respectively, but these val-ues are probably higher. We still have to quantify the significance of these uncertainties in thepreparation of cross sections, which will be postponed for future work. In addition, we verifythat the single effective pebble approach works well for the preparation of region averaged crosssections in the infinite domain approximation. Nevertheless, there are significant discrepanciesin the cross sections when compared to the multi-pebble model. This could affect the predictionof peak values and in the depletion calculation. We conclude that is highly desirable for futurestudies with Griffin to be able to handle both the ?effective? pebble approximation and the multi-pebble approach for the various pebble burnup groups. This enables Griffin users the flexibilityto perform higher-fidelity studies. Finally, we initiate the preparation of cross sections for variouscore regions from the full core Serpent reference model. We quantify the differences in 26 groupcross sections from infinite domain models. These reference cross sections will serve to validatethe double heterogeneity, self-shielding, and spectrum-correction methods in Griffin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Initial study on cross-section generation requirements for a PBR equilibrium core

A Serpent model of the equilibrium core HTR-PM small modular nuclear reactor in China, was developed for use in cross-section preparation studies in order to guide methods development for the Griffin reactor multiphysics application. The model includes detailed isotopics for 10 distinct pebble burnup groups in 126 core zones with unique fuel and moderator temperatures obtained from a coupled neutronics-thermal-fluids equilibrium core calculation using Griffin-Pronghorn. A sensitivity study of the fuel and moderator temperatures for various core regions was performed with the MOOSE stochastic tools. The results show that the uncertainties are, not unexpectedly, dominated by the value of the fluid temperature and that the power level, heat transfer coefficient and effective conduction to neighboring pebbles and fluid constitute, at best, second order effects. The temperature uncertainty range varies from 28 K to 57 K between the core entry and exit planes, respectively, but these values are probably higher. We still have to quantify the significance of these uncertainties in the preparation of cross-sections in future work. In addition, we verified that the effective pebble approximation used in the PEBBED and V.S.O.P. computer codes works well for the preparation of region averaged cross-sections. Nevertheless, there are some discrepancies in the cross-sections when compared to the multi-pebble model, which could affect the prediction of peak values and the depletion calculation. We conclude that is highly desirable for future studies with Griffin to be able to handle both the 'effective' pebble approximation and the multi-pebble approach for various pebble burnup groups. This enables Griffin users with the flexibility to perform higher-fidelity studies. Finally, we initiated the preparation of cross-sections for various core regions from the full core Serpent reference model. We quantified the differences in 26 group cross-sections from infinite domain models versus the full core approach. These reference cross-sections will serve to verify the double heterogeneity, self-shielding, and spectrum-correction methods in Griffin. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

An in-depth field validation of “DUSST”: A novel low-maintenance soiling measurement device

This study presents indoor and field validation results for two versions of the “DUSST” optical soiling sensor, intended to be a low-cost and low-maintenance device for measuring photovoltaic soiling losses. Indoor testing covers irradiance calibration and temperature dependencies, which are necessary to achieve high accuracy, low uncertainty field measurements. Field testing includes an array of different environments including Saudi Arabia, California, Utah, and Colorado. DUSST versions include a configuration with a 530-nm light emitting diode (LED) (discussed in previous work) and a unit with seven white LEDs and a polycarbonate collimating optic. The new design increases light intensity fivefold and demonstrates a single linear calibration coefficient is effective to measure soiling losses as high as 75%. Field data from Utah and California demonstrate that daily soiling loss measurements and soiling rate calculations closely match both reference cell and full-size module measurements of soiling losses and soiling rates. Corrective methods employed on the Utah DUSST sensor suggest that it is possible to achieve measurement errors as low as ±0.1% at two standard deviations. Field data from both Colorado and Saudi Arabia demonstrate that LED lens soiling can occur and that further design optimizations are needed. The lesson learned from all the field deployment locations suggests directions for future design improvements.

14 SOLAR ENERGY↗
DOE OSTI2024

The Influence of Residual Stress on Fatigue Crack Growth Rates in Stainless Steel Processed by Different Additive Manufacturing Methods

The properties and microstructure of Type 304L stainless steel produced by two additive manufacturing (AM) methods—directed energy deposition (DED) and powder bed fusion (PBF)—are evaluated and compared. Localized heating and steep temperature gradients of AM processes lead to significant residual stress and distinctive microstructures, which may be process-specific and influence mechanical behavior. Test data show that materials produced by DED and PDF have small differences in tensile strengths but clear differences in residual stress and microstructural features. Measured fatigue crack growth rates (FCGRs) for cracks propagating parallel to and perpendicular to the build directions differ between the two AM materials. To separate the influences of residual stress and microstructure, K-control test procedures with decreasing and constant stress intensity factor ranges are used to measure FCGRs in the near-threshold regime (crack growth rates ≤ 1 × 10 −8 m/cycle). Residual stress is quantified by the residual stress intensity factor, K res , measured by the online crack compliance method. Correcting the FCGR data for differences in K res brings results for specimens of the two AM materials into agreement with each other and with results for wrought specimens, when the latter are corrected for crack closure. Differences in microstructure and tensile strength have an insignificant influence on FCGRs in these tests.

additive manufacturing↗