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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 OSTI2018

The Determination of Residual Stress in Quenched and Cold-Compressed 7050 Aluminum Alloy T-Section Forgings by the Contour Method and Neutron Diffraction

Residual stresses were determined through the thickness of quenched and quenched followed by cold compression 7050 aluminum alloy T-section forgings using the contour method and neutron diffraction. 7050 T-section forgings are used for the manufacture of the connecting joints of wing and fuselage. Inevitably high residual stresses are introduced during the quenching process of 7050 T-section forgings, which could be reduced by cold compression to overcome the effect of residual stress on machining deformation. The longitudinal residual stresses obtained by the two techniques achieved good agreement in both trend and magnitude in both the quenched and quenched followed by cold compression 7050 T-section forgings. The stress-free lattice spacing of Al(311), the Bragg reflection used for the neutron measurements, was obtained from a 5-mm slice using the plane-stress condition, and its variation through the thickness is insignificant in both the quenched specimen and quenched followed by cold compression specimen. A comparison of the residual stresses in the quenched specimen and quenched followed by cold compression specimen showed significant changes in range of residual stresses from (− 304, 262 MPa) induced by quenching process to (− 125, 142 MPa) due to 3% cold compression. The percentage reduction in residual stress in the quenched specimen due to 3% cold compression was (46, 59%).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Residual Stress Measurements of Cr-coated Cladding

Accident-tolerant fuel concepts for light-water reactor applications have been developed and tested in diverse research programs around the world. Industry teams have developed coated cladding concepts using different coating application methods, such as physical vapor deposition and coldspraying. Recently, variations in thickness and application method were investigated, and their effects on the microstructure and mechanical properties were reported. The results suggest an increase in performance in an unirradiated state, however, it remains unclear what phenomenon drove this performance. One explanation to this performance is associated with the coating process imparting a residual stress. Residual stress analysis was performed on coatings produced with various process parameters to understand how a thin layer of Cr impacts the mechanical properties after coating application and after simulated operating conditions. The gathered information is intended to address safety concerns or support margin identification related to accident-tolerant fuels and to support subsequent modeling and simulation efforts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Investigation of the Effect of Residual Stress Gradient on the Wear Behavior of PVD Thin Films

The control of residual stresses has been seldom investigated in multilayer coatings dedicated to improvement of wear behavior. Here, we report the preparation and characterization of superposed structures composed of Cr, CrN and CrAlN layers. Nano-multilayers CrN/CrAlN and Cr/CrN/CrAlN were deposited by Physical Vapor Deposition (PVD) onto Si (100) and AISI4140 steel substrates. The Cr, CrN and CrAlN monolayers were developed with an innovative approach in PVD coatings technologies corresponding to deposition with different residual stresses levels. Composition and wear tracks morphologies of the coatings were characterized by scanning electron microscopy, high-resolution transmission electron microscopy, atomic force microscopy, x-ray photoelectron spectroscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction and 3D-surface analyzer. The mechanical properties (hardness, residual stresses and wear) were investigated by nanoindentation, interferometry and micro-tribometry (fretting-wear tests). Observations suggest that multilayer coatings are composed mostly of nanocrystalline. The residual stresses level in the films has practically affected all the physicochemical and mechanical properties as well as the wear behavior. Consequently, it is demonstrated that the coating containing moderate stresses has a better wear behavior compared to the coating developed with higher residual stresses. The friction contact between coated samples and alumina balls shows also a large variety of wear mechanisms. In particular, the abrasive wear of the coatings was a combination of plastic deformation, fine microcracking and microspallation. The application of these multilayers will be wood machining of green wood.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Residual stresses in polymer matrix composite laminates

Residual stresses in composites are induced during fabrication and by environmental exposure. The theory formulated can describe the shrinkage commonly observed after a thermal expansion test. Comparison between the analysis and experimental data for laminates of various material systems indicates that the residual stress-free temperature can be lower than the curing temperature, depending on the curing process. Effects of residual stresses on ply failure including the acoustic emission characteristics are discussed.

Hahn, H. T.↗
DOE OSTI2019

Correlation of Tensile Deformation-Induced Strain in HSLA Steel with Residual Stress Distribution

During service, due to the dynamic loading rates encountered, structural components experience varying levels of plastic deformation which leads to changes in the mechanical behavior of materials. The dynamic loading leads to non-homogenous plastic deformation which changes the residual stress distribution. In this study, the magnitude and distribution of residual stress in tensile tested specimens of high-strength low-alloy steel were investigated using x-ray diffraction technique, by varying the deformation rate. Tensile testing was performed at four different strain rates, and residual stress measurement was done along the length of the fractured specimens. Distribution of residual stress was observed all along the length of the specimens which is attributed to the varying levels of plastic deformation. Measured residual stresses are correlated with elastic strain and plastic strain obtained from the tensile tests. Consistent decrease in the magnitude of residual stress with an increase in plastic strain is observed with decreasing strain rate at the necking region. Specimen with lower yield strength experienced higher plastic strains, hence lower elastic residual stresses. The reasons for the observed distribution of residual stress are discussed with XRD peak broadening associated with plastic deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Residual Stresses in Explosively Welded Plates Made of Titanium Grade 12 and Steel with Interlayer

Distributions of residual stress components in explosively welded three-layer plate composed of titanium Grade 12, titanium Grade 1 and SA516 Grade 70 steel are investigated in this paper. The study applied the sectioning and the hole-drilling strain gage methods for residual stress measurement. The results have shown an inhomogeneous residual stress distribution, approximated by fourth-order polynomial along the thickness of a three-layer plate. Biaxial compressive residual stress state is observed in titanium Grade 12 and Grade 1 layers which change to tensile type in the vicinity of the interface between titanium Grade 1 and steel. Microstructure observation reveals the presence of the adiabatic shear bands in titanium Grade 12 layer at the interface with titanium Grade 1 interlayer. The observed distribution of residual stress components is justified by the occurrence of the shock wave phenomena.

36 MATERIALS SCIENCE↗
NASA NTRS1984

The Effect of Creep on the Residual Stresses Generated During Silicon Sheet Growth

The modeling of stresses generated during the growth of thin silicon sheets at high speeds is an important part of the EFG technique since the experimental measurement of the stresses is difficult and prohibitive. The residual stresses which arise in such a growth process lead to serious problems which make thin Si ribbons unsuitable for fabrication. The constitutive behavior is unrealistic because at high temperature (close to the melting point) Si exhibits considerable creep which significantly relaxes the residual stresses. The effect of creep on the residual stresses generated during the growth of Si sheets at high speeds was addressed and the basic qualitative effect of creep are reported.

Hutchinson, J. W.↗
DOE OSTI2024

Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Dimensional tolerances for high-speed-machined aluminum products continue to tighten due to the demand for automated assembly of complex monolithic parts in aerospace and other industries. Understanding the contribution of inherent residual stress in wrought Al 7050-T7451 plate, common in aircraft manufacture, to distortion of high-aspect-ratio machined parts is critical but remains problematic due to the alloy's low residual stress magnitude over large geometries. Prior investigations into residual stress effects on machined part distortion suffer inadequate characterizations of the wrought material stress field, either because of low fidelity due to “slitting” methods, confounding effects in machined-layer removal methods, or small sample size when using neutron diffraction (ND). In this work, inherent residual stress is measured via ND at 860 locations in a 90.5 mm thick Al 7050-T7451 plate having dimensions 399 mm in the rolling direction and 335 mm in the transverse direction. Unlike prior studies, the ND residual stress is reconstructed using an iterative algorithm to ensure fully compatible, equilibrated 3D field prior to examining its effect on distortion. Further, the findings from simulations and experiments show that inherent residual stress alone could distort a high-aspect-ratio part beyond aerospace industry requirements, that slitting measurements may not sufficiently characterize residual stress for predicted distortion, and that parts machined from different plate thickness locations could exhibit reversed distortion patterns. Thus, research into distortion prediction that considers machining should carefully characterize and reconstruct inherent residual stress so that the coupled machining effects are accurately modeled.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Simultaneous optimization of hatching orientations and lattice density distribution for residual warpage reduction in laser powder bed fusion considering layerwise residual stress stacking

The reduction in the residual warpage generated via fabrication is an emerging issue in metals’ laser powder bed fusion additive manufacturing (AM). One solution from a design for additive manufacturing (DfAM) perspective is to arrange a hatching strategy that utilizes the asymmetry of the residual stress generated from a molten pool. Another approach is to arrange the geometry of the parts, such as forming an inner lattice structure to arrange the effective stiffness. In this study, the simultaneous optimization of the laser hatching orientation and lattice density distribution was conducted to minimize the residual warpage in lattice infill structures and confirm their synergetic effect. The mutual effect of each layer was highlighted when considering the mechanical background of the optimal results because an imbalance in the residual stress caused the warpage of the AM parts between the layers. The proposed methodology was validated via experimental verification using a quasi-2D plate, 3D bracket, and 3D connecting-rod design problems. The residual warpage in the quasi-2D study, measured as the edge’s vertical deformation, was reduced from 23.4% to 39.4% compared with the benchmark design. In the 3D studies, the warpage reductions ranged from 13.1% to 20.7%.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Patterns of residual stresses due to welding

Residual stresses caused by welding result from the nonuniform rate of cooling and the restrained thermal contraction or non-uniform plastic deformation. From the zone of extremely high temperature at the weld, heat flows into both the adjoining cool body and the surrounding atmosphere. The weld metal solidifies under very rapid cooling. The plasticity of the hot metal allows adjustment initially, but as the structure cools the rigidity of the surrounding cold metal inhibits further contraction. The zone is compressed and the weld is put under tensile stresses of high magnitude. The danger of cracking in these structural elements is great. Change in specific volume is caused by the change in temperature.

Botros, B. M.↗
NASA NTRS1985

Finite element analysis of residual stress in plasma-sprayed ceramic

Residual stress in a ZrO2-Y2O3 ceramic coating resulting from the plasma spraying operation is calculated. The calculations were done using the finite element method. Both thermal and mechanical analysis were performed. The resulting residual stress field was compared to the measurements obtained by Hendricks and McDonald. Reasonable agreement between the predicted and measured moment occurred. However, the resulting stress field is not in pure bending.

Mullen, R. L.↗
NASA NTRS2015

Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

Newman, John A.↗
NASA NTRS1976

Longitudinal residual stresses in boron fibers

A method of measuring the longitudinal residual stress distribution in boron fibers is presented. The residual stresses in commercial CVD boron on tungsten fibers of 102, 142, and 203 microns (4, 5.6, and 8 mil) diameters were determined. Results for the three sizes show a compressive stress at the surface 800 to -1400 MN/sq m 120 to -200 ksi), changing monotonically to a region of tensile stress within the boron. At approximately 25 percent of the original radius, the stress reaches a maximum tensile 600 to 1000 MN/sq m(90 to 150 ksi) and then decreases to compressive near the tungsten boride core. The core itself is under a compressive stress of approximately -1300 MN/sq m (-190 ksi). The effects of surface removal on core residual stress and core-initiated fracture are discussed.

Behrendt, D. R.↗
NASA NTRS1992

The effects of uneven fiber spacing on thermal residual stresses in a unidirectional SCS-6/Ti-15-3 laminate

High residual stresses develop in SCS-6/Ti-15-3 composites during cooldown from the fabrication temperature; these residual stresses can effect the mechanical and physical properties of the composite. Discrete fiber-matrix finite element models were used to study the residual stresses due to the temperature change during the fabrication process, including the effects of uneven fiber spacing, the free surface, and increased fiber volume fractions. To accurately model the effects of the free surface, it is only necessary to model one fiber through the thickness. Below the first ply, the analysis predicts stress distributions that are identical to the infinite array predictions. For uneven fiber space less than 0.042 mm in an interior ply, the maximum hoop stress was predicted to occur between fibers within a ply and to increase as the fiber spacing decreased. The maximum hoop stress correlated well with the observed radial cracking between fibers. For the case of touching fibers, the analysis predicted tensile radial stresses at the fiber-matrix debonding during the fabrication cooldown. Identical trends were predicted for uneven fiber spacing in surface plies with slightly greater values of maximum stresses. The analysis predicted matrix yielding to occur upon cooldown when the edge-to-edge fiber spacing was less than or equal to 0.022 mm. The stress distributions preidcted for increasing fiber volume fractions were similar to those predicted for decreasing the fiber spacing for two adjacent fibers within a ply.

Bigelow, Catherine A.↗
DOE OSTI2023

Impact of Plate Thickness and Joint Geometry on Residual Stresses in 347H Stainless Steel Welds

Weldments of 347H stainless steel are potentially susceptible to stress relaxation cracking at elevated service temperatures. Mitigation of stress relaxation cracking susceptibility within a multipass weld requires a good understanding of welding practices and manufacturing techniques to control high tensile residual stresses. Here in this work, the dependence of residual stress distribution in 347H stainless steel on base plate thickness, joint geometry design, and preheating condition was systematically investigated by using three-dimensional finite element models. The finite element models were validated through good agreement between neutron diffraction measurements and calculated elastic strains. The single-V-groove welds with and without a preheating step all produced similar peak von Mises residual stresses, above 450 MPa, within both the fusion zone and heat-affected zone (HAZ). In plates thicker than 0.5 in. (12.7 mm), high tensile residual stress could be observed in a relatively large area, from the middle of the plate thickness to underneath the top surface. A double-V groove shifted the high tensile stress area to the middle thickness of the weld. A single-J-groove weld was able to confine the residual stress to a very small region near the middle thickness within the fusion zone and suppressed the von Mises residual stress within the HAZ to below 400 MPa.

14 SOLAR ENERGY↗
DOE OSTI2021

Residual stress analysis of aluminum nitride piezoelectric micromachined ultrasonic transducers using Raman spectroscopy

In this study, the Raman biaxial stress coefficients K II and strain-free phonon frequencies ω 0 have been determined for the E 2 (low), E 2 (high), and A 1 (LO) phonon modes of aluminum nitride, AlN, using both experimental and theoretical approaches. The E 2 (high) mode of AlN is recommended for the residual stress analysis of AlN due to its high sensitivity and the largest signal-to-noise ratio among the studied modes. The E 2 (high) Raman biaxial stress coefficient of ₋3.8 cm₋1/GPa and strain-free phonon frequency of 656.68 cm ₋1 were then applied to perform both macroscopic and microscopic stress mappings. For macroscopic stress evaluation, the spatial variation of residual stress was measured across an AlN-on-Si wafer prepared by sputter deposition. A cross-wafer variation in residual stress of ~150 MPa was observed regardless of the average stress state of the film. Microscopic stress evaluation was performed on AlN piezoelectric micromachined ultrasonic transducers (pMUTs) with submicrometer spatial resolution. These measurements were used to assess the effect of device fabrication on residual stress distribution in an individual pMUT and the effect of residual stress on the resonance frequency. At ~20 μm directly outside the outer edge of the pMUT electrode, a large lateral spatial variation in residual stress of ~100 MPa was measured, highlighting the impact of metallization structures on residual stress in the AlN film.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Abrasive Grinding on Through-Section Residual Stresses on Bearing Steel

In today’s industrial world, bearings are used in traditional applications such as automotive, steel mills, paper mills, railways as well as high precision applications such as aerospace, medical, renewable energy etc. Regardless of application, residual stresses play an important role in the service life of a bearing. In general, bearings experience Hertzian stresses in the order of 2-3 GPa with maximum stresses generated in the subsurface. Depending upon the magnitude and nature (tensile or compressive), the residual stresses enhance or reduce the application stresses. The residual stresses are generated during each stage of manufacturing process. For bearing components, the manufacturing stages include – tube rolling, green machining followed by heat treatment and final finishing. Majority of bearings are finished using abrasive grinding to achieve the final size and shape. The work holding and material removal during the grinding process can cause significant distortion. Distortion of bearing components is ab significant issue, especially for thin sectioned components, leading to high scrap rates. In this study, diffraction was utilized to understand the evolution of through thickness residual stresses after abrasive grinding on a thin walled bearing component. The results from neutron diffraction were coupled with distortion measurement especially the out of roundness to understand the effect of the final processing on the residual stress state present in the bearings.

Bedekar, Vikram↗
DOE OSTI2018

Fatigue crack growth rates of X100 steel welds in high pressure hydrogen gas considering residual stress effects

Fatigue crack growth rate (FCGR) data were measured in high pressure hydrogen gas versus stress intensity factor range (ΔK) in specimens removed from a X100 welded steel pipe. Three distinct regions of the pipe weld were examined: base metal, weld fusion zone, and heat affected zone. Tests were performed at a load ratio (R) of 0.5, frequency of 1 Hz, and at a hydrogen gas pressure of 21 MPa. Tests were also performed in air at 10 Hz as a reference. Fatigue crack growth rates were observed to be over an order of magnitude higher for tests performed in hydrogen compared to the rates from tests in air. Residual stress measurements were collected on identical specimens cut from the base metal, weld, and heat affected zone to account for their influence on measured FCGR data. The slitting method provided residual stress and residual stress intensity factor (K res ), the effect of which was removed from the FCGR data using K norm in order to provide a more direct comparison of crack growth resistance of the base metal, weld and heat affected zone. Prior to accounting for residual stress, FCGR in hydrogen gas appeared to be highest in the weld fusion zone. Furthermore, after accounting for residual stress effects, the weld fusion zone FCGR data converged to the base metal FCGR data, which underscores the importance of accounting for residual stress effects when assessing fatigue performance.

42 ENGINEERING↗