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DOE OSTI2023

Device architectures having engineered stresses

The present disclosure relates to a method that includes depositing a spalling layer onto a surface that includes a substrate, depositing a device comprising a III-V material onto the spalling layer, resulting in the forming of a stack, and dividing the stack substantially at a plane positioned within the spalling layer to form a first portion that includes the substrate and a second portion that includes the PV device, where the spalling layer includes a first layer configured to provide a compressive stress and a second layer configured to provide a tensile stress, the first layer and the second layer form an interface, the dividing occurs as result of the interface, and the compressive stress and the tensile stress are strain-balanced so that a total strain within the spalling layer is approximately zero.

Steiner, Myles Aaron↗

DOE OSTI2020

Oxidation of 3D-printed SiC in air and steam environments

Here, the high-temperature oxidation of additively manufactured and chemically vapor infiltrated (3D-printed SiC) has been compared to chemical vapor deposited (CVD) SiC. 100-h isothermal exposures were conducted at 1425° and 1300°C at 1 atm under both dry air and steam environments. A SiC reaction tube was utilized to reduce silica volatility. After steam oxidation at 1425° and 1300°C, on the 3D-printed SiC surface, which was intrinsically rougher than the CVD surface, scales were 70%–90% thicker at the convex regions compared to concave/flat regions. In the convex regions, large cracks perpendicular to the oxidizing interface were observed. After dry air oxidation, scale thicknesses were comparable between 3D-printed SiC and CVD SiC, regardless of geometry. Finite element modeling, conducted to elucidate the relationship between SiC geometry and ß- to α-cristobalite transformation stress, determined cristobalite transformation tensile stresses to be on the order of 103 MPa during cool down, assuming a 6 vol% reduction. Compared to flat SiC substrates, tensile transformation stresses were elevated at concave regions and relaxed at convex regions. Combined with specimen mass gain (accounting for the rougher surface) of 3D-printed SiC being 15%–32% higher for 3D-printed SiC after 1300°C and 1425°C steam oxidation, the work presented concludes that the increased oxidation of 3D-printed SiC is primarily caused by tensile hoop stresses driven by oxidation volume expansion. Lastly, the efficacy of the 3D-printing method is demonstrated through the production of tristructural isotropic imbedded 3D-printed SiC fuel forms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1971

Stress-corrosion cracking in metals

Criteria and recommended practices for preventing stress-corrosion cracking from impairing the structural integrity and flightworthiness of space vehicles are presented. The important variables affecting stress-corrosion cracking are considered to be the environment, including time and temperature; metal composition, and structure; and sustained tensile stress. For designing spacecraft structures that are free of stress-corrosion cracking for the service life of the vehicle the following rules apply: (1) identification and control of the environments to which the structure will be exposed during construction, storage, transportation, and use; (2) selection of alloy compositions and tempers which are resistant to stress-corrosion cracking in the identified environment; (3) control of fabrication and other processes which may introduce residual tensile stresses or damage the material; (4) limitation of the combined residual and applied tensile stresses to below the threshold stress level for the onset of cracking throughout the service life of the vehicle; and (5) establishment of a thorough inspection program.

Source record↗

NASA NTRS1981

Analysis of the tensile stress-strain behavior of elastomers at constant strain rates. I - Criteria for separability of the time and strain effects

A theoretical analysis of the tensile stress-strain relation of elastomers at constant strain rate is presented which shows that the time and the stress effect are separable if the experimental time scale coincides with a segment of the relaxation modulus that can be described by a single power law. It is also shown that time-strain separability is valid if the strain function is linearly proportional to the Cauchy strain, and that when time-strain separability holds, two strain-dependent quantities can be obtained experimentally. In the case where time and strain effect are not separable, superposition can be achieved only by using temperature and strain-dependent shift factors.

Hong, S. D.↗

DOE OSTI2022

Porosity evolution under increasing tension in wire-arc additively manufactured aluminum using in-situ micro-computed tomography and convolutional neural network

Internal defects such as porosities are often formed in additively manufactured metal components. The pores nucleate, grow, and coalesce to form cracks under loads, leading to eventual catastrophic failure. Here, in this paper, the full-field porosity evolution, including pore growth and coalescence in a wire-arc additively manufactured (WAAM) aluminum alloy cylinder under tension is observed with in-situ X-ray micro-computed tomography (μCT). The pore size distribution, density, and tensile stress are calculated from the volumetric images analyzed by a convolutional neural network (CNN) algorithm, which provides rapid analysis of 12,950 slice images from μCT volumetric images at the reference state and 13 tensile strains. The results show the quantitative evolution of the growth and coalescence of macropores under tension. A strong correlation is found between the local pore volume fraction and the true tensile stress when the tensile strain is larger than 5%.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Laser repair welding of irradiated alloy 182

Welding repair of irradiated nickel-based alloys, such as Alloy 182, poses a significant challenge due to helium-induced cracking (HeIC) and grain boundary degradation (GBD) in the heat affected zone, driven by helium accumulation at grain boundaries and welding-induced tensile stresses. This study investigates the weldability of irradiated Alloy 182 up to 15 wppm doped boron using both conventional laser welding and the Auxiliary Beam Stress Improved (ABSI) laser welding technique. While HeIC was observed at the weld toe of the entry pass in both methods due to the higher effective heat input associated with the initial pass directly on the base metal, no additional cracking occurred elsewhere, even at elevated helium concentrations. Optical and scanning electron microscopy analysis revealed that the ABSI technique, which introduces additional compressive stresses to counteract solidification-induced tensile stresses, significantly reduced GBD formation, lowering its total count from 1,230 to 339 and decreasing both average and maximum GBD lengths. In conclusion, these results demonstrate that the ABSI technique is a promising approach to mitigate helium-induced damage and improve the weldability of irradiated Alloy 182, offering a viable solution for structural repairs for long-term operation of existing nuclear reactors.

grain boundary degradation↗

NASA NTRS1981

Stress-concentration factors for finite orthotropic laminates with a pin-loaded hole

Stresses were calculated for finite size orthotropic laminates loaded by a frictionless steel pin in a circular hole of the same diameter. The calculations were based on finite element analyses for six laminates. Stress concentration factors, based on nominal bearing stress, were determined for wide ranges of the ratios of width to diameter, w/d and edge distance to diameter, e/d. An infinite laminate case was analyzed for each laminate. Orthotropy had a significant influence on the tensile stress concentration at the hole. For example, the stress concentration factors for the infinite laminate cases ranged from 0.82 to 2.16, compared with 0.87 for the quasi-isotropic laminate. The finite widths and edge distances strongly influenced the tensile stress concentration. For the practical range w/d or = 3, the peak tensile stresses were as much as 80% larger than the infinite laminate reference value. For e/d or = 3, these stresses were amplified by as much as 50%. In contrast, the finite width and edge distance had little effect on shear-out and bearing stress concentrations.

Crews, J. H., Jr.↗

DOE OSTI2016

Corrosion test of LWR cladding tubes in high temperature seawater

In the case of cooling system failure in spent fuel pools (SFP) due to station black out and/or loss of coolant accidents, a pool water level must be kept high enough to avoid overheat of spent fuels. Seawater is one of the candidate coolant materials in such emergencies. In the present work, we have studied the corrosion behavior of zirconium alloys in seawater. Tube samples of Zircaloy-2 and -4 claddings were immersed in artificial seawater (3, 10 and 20 wt.%) at high temperature (80 - 85 Celsius degrees). Boric acid was added to the seawater at a corrosion test of Zircaloy-4. Two types of specimens were prepared according to the simulation of circumferential tensile stress. One was a plugged tube specimen, which was pressurized to around fuel rod pressure in a spent fuel pool by argon gas. Another specimen was of C-ring shape, where large circumferential tensile stress was partially induced at the surface. A notch was longitudinally grooved to increase the local tensile stress on some of the C-ring specimens. The specimen surface was observed by a scanning electron microscopy (SEM) after the corrosion test. After the 200 day long corrosion test for the plugged tube specimens without boric acid, Mg(OH){sub 2} deposits were observed on the surface of Zircaloy-2 and -4 specimens whereas Mg(OH){sub 2} was not observed with boric acid because of probably a lower pH. Neither pitting corrosion nor stress corrosion cracking (SCC) was observed on the surface of all plugged tube specimens. Only in the C-ring specimens in 20 wt.% seawater without boric acid and in 3 and 10 wt.% seawater with boric acid, small cracks were observed at the notch. The results of the present work show that Zircaloy-2 and -4 have a high tolerance towards corrosion and SCC in high temperature seawater.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Rotational flexural strength of cylindrical brittle specimens

Conventional static flexural strength testing of brittle cylindrical rods only subjects a small fraction of the entire specimen's area or volume to the maximum tensile stress. Thus, a nonconservative measured strength likely results since most flaws on the surface or in the bulk are not subjected to a sufficiently high tensile stress that can cause fracture. Here, to mitigate this, a rotational flexural tester and corresponding test method were developed whereby rotation and monotonically increasing three-point flexure were superimposed to investigate fracture response of solid glass cylinders. This combination of rotation and flexure subjects more area and volume of a cylindrical test specimen to tensile stress than a standard static (nonrotating) flexural test. As anticipated, failure stresses were lower for the rotational flexural test. Expressions for effective area and volume are provided for rotating solid rods and tubes subjected to three-point, four-point, uniform, and uniformly distributed load bending configurations.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Projected Seismic Activity at the Tiger Stripe Fractures on Enceladus, Saturn, From an Analog Study of Tidally Modulated Icequakes Within the Ross Ice Shelf, Antarctica

Abstract Dissipation of tidal energy is expected to generate seismicity on icy‐ocean worlds; however, the distribution and timing of this seismic activity throughout an orbital cycle is not known. We used new observations from an icy‐ocean‐world analog environment on Earth to examine the relationship between tidally driven tensile stress and seismic activity within an ice shell. We investigated a pair of rifts within Antarctica's Ross Ice Shelf which are tidally stressed in a manner analogous to the orbital cycle of tidal stress experienced by Enceladus' Tiger Stripe Fractures. We found that seismic activity at the Antarctic rifts is sensitive to both the amplitude and the rate of tensile stress across the rifts. We combined these findings with calculated stress values along Enceladus' Tiger Stripe Fractures to predict seismic‐activity levels expected along the ice‐shell fractures. We predict a peak in seismicity along the four Tiger Stripe Fractures when Enceladus is 90°–120° past pericenter in its orbit around Saturn, at which point tensile stresses would reach ∼2/3 of their maximum value. We also used the magnitude distribution of icequakes along Antarctic rifts to investigate implications for the likely size of stick‐slip rupture patches along icy faults on Enceladus. Our findings predict that the Tiger Stripe Fractures should produce sustained, low‐magnitude seismic events that involve rupture along discrete portions of each fracture's total length. We predict that seismicity would fall to 50% of peak levels when stresses across the Tiger Stripe Fractures are dominantly compressional.

Olsen, Kira G.↗

DOE OSTI2018

Assessment of failure modes of monolithic fuel plates

Monolithic fuel is a fuel form that is considered for the conversion of high performance research reactors. In order to qualify this new fuel system, the fuel plates should meet the safety standards and perform well in reactor. The fuel system must maintain its mechanical integrity, sustain a geometric stability and should have stable and predictable irradiation behavior. The requirement to maintain mechanical integrity under normal operating conditions is primarily demonstrated by a successful testing of fuel plates up to the limiting conditions defined by the fuel performance envelope, including an adequate margin. Although large number of plates have been tested with satisfactory thermo-mechanical performance, post-irradiation examination of plates from previous RERTR-12 experiments have revealed that pillowing occurred in several plates, rendering performance of these plates unacceptable. To address such failures, efforts are underway to define the mechanisms responsible for the in-reactor pillowing, and suggest improvements to the fuel plate design and operational envelope. For this purpose, selected plates from previous experiments were simulated to understand the thermo-mechanical response of the plates to the fission density and thermally induced stresses. Simulation results were then comparatively evaluated with post-irradiation examinations of selected plates. The simulation results and experimental observations established a possible correlation between failure by plate pillowing, high porosity and a presence of tensile stress state. The study has implied that porosity leading to degradation of material properties, accompanied by a sufficiently large tensile stress state can lead to a pillowing-type failure at reactor shutdown. This paper presents these findings, discusses such failure modes, and the influence of fuel burn-up and power on the magnitude of the shutdown-induced tensile stresses.

42 ENGINEERING↗

DOE OSTI2021

Relating phase transitions to pore size distributions and mechanical mortar properties in CSA-OPC-C$ based systems – The potential impact of delayed straetlingite formation

The scope of this research is to investigate the performance evolution of five ternary CSA-OPC-Cs systems. Time resolved thermodynamic modeling was employed to gain insight into changes in the volume fractions of the hydrating pastes and link these changes to trends in the pore size distributions of the mortars. Pore solution analyses were performed to investigate which hydrates have the potential to exert high crystallization pressures. In three out of five blends the resulting tensile stress exceeded the tensile strength of the materials, resulting in the occurrence of coarse pores, which could be linked to the measured compressive strengths. Two damaging crystallization processes were identified in the investigated blends. One is the continuous precipitation of ettringite at high supersaturation in a system with high anhydrite addition. The other is the delayed crystallization of straetlingite at high supersaturation and crystallization pressure in the confined environment of mature pastes.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Influence of the Ozone Dose Time during Atomic Layer Deposition on the Ferroelectric and Pyroelectric Properties of 45 nm-Thick ZrO 2 Films

Over a decade ago, ferroelectricity was discovered in doped HfO 2 thin films. The HfO 2 -based thin films have attracted much attention due to their remarkable scalability and CMOS compatibility. Other than the HfO 2 -based thin films, the undoped ZrO 2 thin films are understudied despite their commonly reported antiferroelectric behavior. However, being of the same fluorite structure as HfO 2 -based thin films, the undoped ZrO 2 also displayed considerable ferroelectricity as demonstrated in recent studies. Here, 45 nm-thick polycrystalline undoped ZrO 2 films are synthesized using atomic layer deposition with different ozone dose times. The ZrO 2 films are crystallized after atomic layer deposition at 350 °C without anneals. In general, the longer ozone dose time causes a lower in-plane tensile stress and oxygen vacancy content, which help facilitate an irreversible non-polar tetragonal to polar orthorhombic phase transition with electric-field cycling. However, the lower in-plane tensile stress and oxygen vacancy content also stabilize the monoclinic phase so that a long ozone dose time (>17.5 s) reduces the ferroelectric behavior. After wake-up cycles, the ZrO 2 thin film with an ozone dose time of 17.5 s exhibits a remanent polarization of 6 μC·cm –2 and a pyroelectric coefficient of -35 μC·K –1 ·m –2 . Moreover, the wake-up behavior is consistent between the ferroelectric and pyroelectric response. As essential factors in optimizing the growth of fluorite-structure thin films for ferroelectric applications, the in-plane tensile stress and oxygen vacancy content significantly influence the ferroelectric and pyroelectric properties. Additionally, the low thermal budget for processing ferroelectric ZrO 2 thin films is valuable for semiconductor back-end-of-line processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1991

Continuum modeling of catastrophic collisions

A two dimensional hydrocode based on 2-D SALE was modified to include strength effects and fragmentation equations for fracture resulting from tensile stress in one dimension. Output from this code includes a complete fragmentation summary for each cell of the modeled object: fragment size (mass) distribution, vector velocities of particles, peak values of pressure and tensile stress, and peak strain rates associated with fragmentation. Contour plots showing pressure and temperature at given times within the object are also produced. By invoking axial symmetry, three dimensional events can be modeled such as zero impact parameter collisions between asteroids. The code was tested against the one dimensional model and the analytical solution for a linearly increasing tensile stress under constant strain rate.

Ryan, Eileen V.↗

DOE OSTI2019

Geotechnical Concerns of Bayou Choctaw Strategic Petroleum Reserve and Explanations

Geotechnical concerns arise due to the close proximity of the some of the caverns to each other (e.g., Caverns 15 and 17) or to the edge of the salt dome (e.g., Cavern 20). There are nine abandoned caverns, one of which collapsed (Cavern 7) in 1954 and another (Cavern 4) which is believed to be in a quasi-stable condition. This report provides explanations for these geotechnical concerns. The structural integrity of the pillar between BC-15 and 17 is examined. No salt fall is expected through 2045. However, the dilatant damaged area increases with time, especially, at the chimney area of BC-17. One drawdown leach for both caverns could be allowed if they are normally operated as a gallery, depressurized simultaneously. The possibility of a loss in integrity of BC-20 is examined in the salt between the dome edge and the cavern. The edge pillar is predicted to have experienced tensile stress since September 1999, but the small tensile stressed area is predicted to disappear in 2018 because BC-20 is filled fully with brine rather than oil since 2/7/2013. Even though BC-20 is no longer used as an SPR cavern, we need to continue monitoring the cavern integrity. BC-4 is also currently filled with brine and will not hold pressure at the wellhead. The cavern extends upward into the caprock and has no effective salt roof The results indicate that any sort of caprock roof collapse for BC-4 is not imminent but salt falls will likely occur from the near-roof portions of the cavern. The uncertainty due to salt falls illustrates the importance of continued monitoring of the area around BC-4 for behavior such as subsidence and tilt which may indicate a change in the cavern's integrity status.

02 PETROLEUM↗

DOE OSTI2019

Fracture Toughness Evaluation for Spent Nuclear Fuel Clad Systems Using Spiral Notch Torsion Fracture Toughness Test

Many radioactive materials within the nuclear fuel cycle present a significant hazard. Such materials include spent nuclear fuel, high-level waste, legacy waste and other nuclear materials. These materials are often held in long-term storage as an interim stage within their lifecycle, including reuse or disposal. Safety and security of spent nuclear fuel (SNF) interim storage installations and follow-on SNF transportations to its final repository sites are very important, due to a great concentration of fission products, actinides and activation products. Fracture mechanics approach in applying to SNF system reliability investigation, especially for the high burn up (HBU) SNF, during SNF long term dry storage or SNF transportation is necessary due to the inherited flaws and inhomogeneity structures existed in a SNF system from the reactor operation. For instance, such as hydride and oxide formation, surface flaw induced by SNF assembly contact interactions, or internal flaws induced by pellet-clad mechanical interaction (PCMI). However, none of the existing fracture toughness data deal with fuel cladding specific geometry or SNF material conditions, such as cladding structure with the segment fuel pellets configuration and the PCMI mechanism. Consequently, the application of existing fracture toughness data to SNF system reliability investigation can be error prone; thus, the development of an industry-wide consensus fracture mechanics approach is needed. The objective of this research is to develop an in-situ fracture mechanics testing protocol, including the associated analytical procedure, that is suitable for evaluating the SNF fracture toughness. Fracture toughness data was obtained under quasi-static fracture loading using Oak Ridge National Laboratory (ORNL) developed Spiral Notch Torsion Test (SNTT) technology carried out on a biaxial tension/torsion tester. These data will be used to support SNF reliability investigation during long-tern SNF dry storage stage or in the follow-on SNF system transport to the final repository sites. SNTT has been a recent breakthrough in measuring fracture toughness for different materials, including metals, ceramics, concrete and polymers composites. Due to its high geometry constraint and unique loading condition, SNTT can be used to measure the fracture toughness with smaller specimens without concern of size effects. The application of SNTT to brittle materials has been proved to be successful. The micro-cracks induced by original notches in brittle materials could ensure crack growth in SNTT samples. Therefore, no fatigue pre cracks are needed for brittle materials specimens. The application of SNTT to the ductile material to generate valid toughness data will require a test sample with sufficient pre-crack length to increase the sample localized constraint at crack front. Fatigue pre-crack growth techniques with the associated compliance function estimated was developed for estimating the crack penetration depth to monitor the fatigue crack growth evolution. In order to extend SNTT approach to a thin shell cladding structure material, a new testing protocol and the associated analytical procedure for estimating the SNF fracture toughness was developed. The detailed SNTT approach and its estimated fracture toughness for the Zr-4 cladding structure with segment alumina inserts are presented in this report. The SNTT test results indicate that SNTT method is a reliable test approach with good repeatability in applying to Zr-4 cladding material. For the medium and the short crack length, the estimate J Q upon fracture for the baseline Zr-4 cladding is at 285.7 lb/in with 2-sigma uncertainty of 18.59 lb/in., and the associated K Q is at 61.4 Ksi√in. For a long crack length, the crack initialization orientation is apparently deviated from the principle tensile stress contour – 45° spiral crack front (i.e., Mode I + Mode III failure mechanism); and the estimated J Q is at 108 lb/in., the associated K Q is at 37.7 Ksi√in. The estimate Mode I J Q (along the 45° pitch principle tensile stress contour) is at 200 lb/in.; which indicate a significant reduction in the fracture toughness in a tubing structure under mixed mode loading condition, Mode I + Mode III, compared to that of Mode I (tensile stress dominated) alone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Microstructure and mechanical properties of high Mn-containing ferritic-martensitic alloys exposed to cyclical thermal treatment

Substantial residual tensile stress tends to accumulate in currently available high-Cr ferritic martensitic steels that are subjected to cyclical heat treatment, which leads to premature brittle fracture. By tailoring the alloy composition, this thermal cycling can be exploited to induce a high number density of nanoprecipitates and phase transformations countering residual tensile stresses. In this work, three new variants of ferritic-martensitic steels have been designed with computational thermodynamics to meet the goals of mitigating residual tensile stresses by lowering martensite start temperatures and of enhancing mechanical strength and irradiation sink strength by increasing the number density of nanoprecipitates. Furthermore, ctenast materials were subjected to cyclical heat treatment. The thermally cycled samples were evaluated with mechanical testing and microstructural analysis to identify the optimal composition in which figures of merit include low residual stress and a high density of nanoscale MX (M = metal, X = C/N) precipitates, leading to high yield strength with reasonable ductility. The noticeably higher density of nanoprecipitates in the optimal alloy favor its higher yield strength, which is supported by the microstructure-derived yield strength calculation and precipitation kinetics simulation.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Irradiation hardening and ductility loss of Eurofer97 steel variants after neutron irradiation to ITER-TBM relevant conditions

Ten Eurofer97 steel variants, produced by non-standard fabrication-processing routes and modified alloying chemistries, were studied by neutron irradiations in the high flux isotope reactor. The irradiations were performed to ITER-TBM relevant conditions of ~255–350 °C, 2.94–3.24 dpa. We quantified the irradiation-induced degradation of the steels using mechanical property tests. All the steels suffered from irradiation hardening, where a significant increase in Vickers microhardness and yield stress (σ YS ) occurred, accompanied with severe loss of tensile elongation. The extent of hardening was material dependent. For T irr = 300±30 °C, most steels showed σ YS increase in the range of ~30% to as high as ~66%, except for a low temperature tempered steel with σYS increase below 15%. Despite large losses in elongation, most failures were ductile. Significant post-necking ductility was retained with reduction in area (RA) between 65–75%, but <50% for low temperature tempered steels. The ultimate tensile stress to yield stress (σ UTS /σ YS ) ratios decreased significantly after irradiation, highlighting irradiation-induced strain hardening capacity reduction. No major effect of irradiation on the plastic instability stress (σ PIS ) and true fracture stress of the steels was observed. By comparing the tensile stresses in true stress units and with literature, the results suggest that RAFM steel designing should target materials with a large separation between σ PIS and σ YS , to ensure the materials can maintain large work hardening and uniform deformation capability after irradiation. The tensile data of the steels additionally revealed a compelling evidence of an inverse trend between the change in RA and increase in σ YS of the neutron irradiated Eurofer97 type steels.

36 MATERIALS SCIENCE↗