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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

Exemplar for simulation challenges: Large-deformation micromechanics of Sylgard 184/glass microballoon syntactic foams.

Sylgard® 184/Glass Microballoon (GMB) potting material is currently used in many NW systems. Analysts need a macroscale constitutive model that can predict material behavior under complex loading and damage evolution. To address this need, ongoing modeling and experimental efforts have focused on study of damage evolution in these materials. Micromechanical finite element simulations that resolve individual GMB and matrix components promote discovery and better understanding of the material behavior. With these simulations, we can study the role of the GMB volume fraction, time-dependent damage, behavior under confined vs. unconfined compression, and the effects of partial damage. These simulations are challenging and push the boundaries of capability even with the high performance computing tools available at Sandia. We summarize the major challenges and the current state of this modeling effort, as an exemplar of micromechanical modeling needs that can motivate advances in future computing efforts.

36 MATERIALS SCIENCE↗

Structure/property (constitutive and spallation response) of additively manufactured 316L stainless steel

For additive manufacturing (AM) of metallic materials, the certification and qualification paradigm needs to evolve as there is currently no broadly accepted “ASTM- or DIN-type” additive manufacturing certification process or AM-produced material specifications. Accordingly, design, manufacture, and subsequent implementation and insertion of AM materials to meet engineering applications requires detailed quantification of the constitutive (strength and damage) properties of these evolving materials, across the spectrum of metallic AM methods, in comparison/contrast to conventionally-manufactured metals and alloys. For this paper, cylindrical samples of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1 kW Yb-fiber laser. The microstructure of the AM-316L SS was characterized in both the “as-built” AM state and following a heat-treatment designed to obtain full recrystallization to facilitate comparison with annealed wrought 316L SS. The constitutive behavior as a function of strain rate and temperature was characterized and is compared to that of annealed wrought 316L SS plate material. The dynamic shock-loading-induced damage evolution and failure response of all three 316L SS materials was quantified using flyer-plate impact driven spallation experiments at peak stresses of 4.7 and 6.5 GPa. The spall strength of AM-produced 316L SS and the recrystallized-AM-316L SS were found to decrease with increasing peak shock stress while the annealed wrought 316L SS spall strength remained essentially constant. Finally, the damage evolution, characterized using optical metallography and electron-backscatter diffraction (EBSD), was found to vary significantly across the three 316L SS microstructures while the three samples loaded to a peak shock stress of 6.5 GPa displayed only ~12% differences in spall strength.

316L SS↗

Predicting fracture behavior in single crystal nickel using a coupled crystal plasticity phase field damage approach

Understanding the fracture behavior of single crystal metals is critical for predicting material performance under mechanical loading. Here, in this study, we investigate the fracture characteristics of single crystal nickel tensile bars using a crystal plasticity coupled phase field damage (CP-PFD) model. Experimental tensile tests were conducted on 15 specimens spanning five crystallographic orientations and three thickness variants per orientation. The results revealed two distinct fracture modes: brittle fractures with 45-degree angled surfaces and ductile fractures characterized by significant necking. The CP-PFD model successfully replicated these fracture behaviors, demonstrating strong agreement with experimental observations. The model effectively predicted the strain at which necking and fracture occurred, as well as the orientation-dependent fracture mechanisms. By comparing experimental and simulated fracture surfaces, we establish the CP-PFD model as a robust tool for predicting single crystal behavior and damage evolution. This work provides insight into the microstructural dependence of fracture behavior and establishes a predictive framework for modeling orientation-dependent damage evolution in single-crystal nickel.

Crystal plasticity↗

Dynamic deformation and fracture of single crystal silicon: Fracture modes, damage laws, and anisotropy

Impact fracture of single-crystal Si is critical to long-term reliability of electronic devices and solar cells for its wide use as components or substrates in semiconductor industry. Single-crystal Si is loaded along two different crystallographic directions with a split Hopkinson pressure bar integrated with an in situ x-ray imaging and diffraction system. Bulk stress histories are measured, simultaneously with x-ray phase contrast imaging (XPCI) and Laue diffraction. Damage evolution is quantified with grayscale maps from XPCI. Single-crystal Si exhibits pronounced anisotropy in fracture modes, and thus fracture strengths and damage evolution. For loading along [11¯ 0] and viewing along [001], (1¯1¯0)[11¯ 0] cleavage is activated and induces horizontal primary cracks followed by perpendicular wing cracks. However, for loading along [011¯] and viewing along [111], random nucleation and growth of shear and tensile-splitting crack networks lead to catastrophic failure of materials with no cleavage. The primary-wing crack mode leads to a lower characteristic fracture strength due to predamage, but a more concentrated strength distribution, i.e., a higher Weibull modulus, compared to the second loading case. Furthermore, the sequential primary cracking, wing cracking and wing-crack coalescence processes result in a gradual increase of damage with time, deviating from theoretical predictions. Particle size and aspect ratios of fragments are discussed with postmortem fragment analysis, which verifies fracture modes observed in XPCI.

36 MATERIALS SCIENCE↗

The damage Mechanics challenge Results: Participant predictions compared with experiment

In this article, We present results from a recent exercise where participating organizations were asked to provide model-based blind predictions of damage evolution in 3D-printed geomaterial analogue test articles. Participants were provided with a range of data characterizing both the undamaged state (e.g., ultrasonic measurements) and damage evolution (e.g., 3-point bending, unconfined compression, and Brazilian testing) of the material. In this paper, we focus on comparisons between the participants’ predictions and the previously secret challenge problem experimental observations. We present valuable lessons learned for the application of numerical methods to deformation and failure in brittle-ductile materials. The exercise also enables us to identify which specific types of calibration data were of most utility to the participants in developing their predictions. Further, we identify additional data that would have been useful for participants to improve the confidence of their predictions. Consequently, this work improves our understanding of how to better characterize a material to enable more accurate prediction of damage and failure propagation in natural and engineered brittle-ductile materials.

36 MATERIALS SCIENCE↗

In-Situ Helium Implantation and TEM Investigation of Radiation Tolerance to Helium Bubble Damage in Equiaxed Nanocrystalline Tungsten and Ultrafine Tungsten-TiC Alloy

The use of ultrafine and nanocrystalline materials is a proposed pathway to mitigate irradiation damage in nuclear fusion components. Here, we examine the radiation tolerance of helium bubble formation in 85 nm (average grain size) nanocrystalline-equiaxed-grained tungsten and an ultrafine tungsten-TiC alloy under extreme low energy helium implantation at 1223 K via in-situ transmission electron microscope (TEM). Helium bubble damage evolution in terms of number density, size, and total volume contribution to grain matrices has been determined as a function of He+ implantation fluence. The outputs were compared to previously published results on severe plastically deformed (SPD) tungsten implanted under the same conditions. Large helium bubbles were formed on the grain boundaries and helium bubble damage evolution profiles are shown to differ among the different materials with less overall damage in the nanocrystalline tungsten. Compared to previous works, the results in this work indicate that the nanocrystalline tungsten should possess a fuzz formation threshold more than one order of magnitude higher than coarse-grained tungsten.

36 MATERIALS SCIENCE↗

A Micro-Mechanism-Based Continuum Corrosion Fatigue Damage Model for Steels

A micro-mechanism-based corrosion fatigue damage model is developed for studying the high-cycle corrosion fatigue of steel from multi-scale viewpoint. The developed physical corrosion fatigue damage model establishes micro-macro relationships between macroscopic continuum damage evolution and collective evolution behavior of microscopic pits and cracks, which can be used to describe the multi-scale corrosion fatigue process of steel. As a case study, the model is used to predict continuum damage evolution and number density of the corrosion pit and short crack of steel component in 5% NaCl water under constant stress amplitude at 20 kHz, and the numerical results are compared with experimental results. It shows that the model is effective and can be used to evaluate the continuum macroscopic corrosion fatigue damage and study microscopic corrosion fatigue mechanisms of steel.

36 MATERIALS SCIENCE↗

A predictive modeling tool for damage analysis and design of hydrogen storage composite pressure vessels

In this study, a predictive modeling tool is developed for damage analysis and design of hydrogen (H 2 ) storage composite pressure vessels. It integrates micromechanics of matrix cracking into a continuum damage mechanics (CDM) description for damage evolution, and three-dimensional (3D) finite element (FE) modeling of the vessel structural response. At the scale of the composite layer (mesoscale), the temperature-dependent stiffness reduction law in terms of the damage variable for transverse matrix cracking is computed using an Eshelby-Mori-Tanaka approach for the initial composite thermoelastic properties and a self-consistent model for the stiffness reduction as a function of the damage variable. While transverse matrix cracking obeying a damage evolution relation can progressively evolve from an initiation to a saturation state, fiber failure is predicted by a micromechanical fiber rupture criterion that accounts for the fiber strength and matrix stress. The implementation of this integrated multiscale modeling model into a 3D FE formulation enables damage analysis and design of H 2 storage composite pressure vessels. The developed tool is illustrated through 3D damage analyses of a cryogenically compressed H 2 storage vessel model subjected to thermomechanical loadings to investigate effects of the helical layer fiber orientation and loading scenario on damage development, vessel integrity and burst pressure.

08 HYDROGEN↗

The Influences of Neutron Irradiation on Aggregate Induced Degradation of Concrete

Reactor cavity concrete, the primary support structure for the reactor pressure vessel (RPV), is exposed to chronic neutron/gamma radiation during normal operation. During long term operation, the interaction of neutron irradiation with the concrete’s constituents may cause premature degradation of the concrete structure, as highlighted by a review of concrete properties in nuclear power plant environments. At high fluence levels, as in biological shielding, neutron irradiation may cause amorphization of the crystalline components of concrete, i.e., mineral aggregates, and volume changes, which are typically expansive in nature. Volume expansion can generate tensile stresses within concrete which can induce microcracking and/or result in debonding of aggregate with the matrix. On the other hand, structural disordering can result in changes in the stability of the phase in aqueous environments. This report presents the findings of investigations performed over 3 years through the collaboration of researchers from University of California, Los Angeles, Arizona State University, and Oak Ridge National Laboratory. The first part of the study addresses the effect of neutron irradiation on the durability of aggregates. Comparisons of aqueous dissolution rates, as a function of pH and temperature, were performed for aggregates that are either pristine (i.e., non-irradiated) or exposed to Ar+ ion irradiation at specified doses. These experimental results were coupled with molecular dynamics simulations of atomic scale changes in the crystallographic structure of the mineral and any resulting changes in physical properties (e.g., density) that result. The second section focuses on macroscopic effects of such changes in aggregate behavior in concrete degradation, primarily through changes in the concrete’s microstructure. Particularly, the effects akin to those originating from alkali-silica reaction (ASR) were evaluated. The project is structured to encompass 6 main tasks, as follows: Task 1: Selection of aggregates in relation to their abundance and mineralogy, and their irradiation Task 2: Molecular dynamics (MD): The effects of irradiation on the atomic disordering of aggregates Task 3: The influences of irradiation on aggregate reactivity Task 4: Reactive-transport simulation of expansive product formation in concrete microstructures Task 5: X-FEM-based modeling of damage evolution due to irradiation-induced aggregates reactions Task 6: Benchmarking, verification and validation of the simulation modules Thus, a rigorous understanding of irradiation-assisted mineral alterations was used to develop a mechanistic degradation model for concrete exposed to neutrons, while considering aspects of: chemical reaction (dissolution and precipitation), mass and ion transport, and damage evolutions. The models developed were embedded in a multi-physics aging code for nuclear components and structures called Grizzly, which allows for benchmarking, verification, and validation against expansion data acquired on concrete undergoing alkali-silica reaction, a physically/chemically equivalent form of degradation that develops in the absence of radiation. These findings provide insight into the sensitivities of minerals to irradiation, by highlighting characteristics of concretes and power plants subject to such risks. The research will aid the nuclear power industry to anticipate and mitigate such risks in light of second license renewals.

36 MATERIALS SCIENCE↗

On the dynamic tensile strength of an FCC metal

The tensile response of ductile, polycrystalline metals is often accompanied by the formation of pores within the material, which coalesce and fail a plane within a metal. This large deformation process is broadly progressive, with a physical path consisting of nucleation, growth, coalescence, and failure, which occur individually over short periods of time. Thus distinct micro-mechanisms operate, each influenced by microstructure, loading path, and loading profile, which remains a significant challenge to represent and predict numerically at the macroscale. In a previous study, the influence of loading path on damage evolution in high-purity tantalum has been presented; in this paper, complimentary measurements are made on a pure, FCC copper. Samples were shock loaded to three different peak stresses using both symmetric impact, and two different composite flyer plate configurations, such that upon unloading, the three samples were subject to nearly identical tensile loading. The damage evolution in the soft-recovered copper samples was then quantified using optical metallography and electron-back-scatter diffraction. We shall compare metallurgical observations, velocimetry histories and simulations to discuss the dynamic failure mechanics observed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Real-time damage characterization for GFRCs using high-speed synchrotron X-ray phase contrast imaging

Here, we report the application of high-speed synchrotron X-ray phase contrast imaging (PCI) in real-time damage characterization for glass fiber reinforced composites (GFRCs) subjected to dynamic loading. Dynamic single-edge notched bending (DSENB) experiments on pre-notched S-2 GFRCs were performed on a modified Kolsky compression bar. During loading, the synchrotron X-ray beam penetrated through the composite specimen from the side to detect damage evolution inside the material. Entire dynamic events were recorded by a high-speed camera as image sequences.0° and 90° unidirectional and cross-ply composites were investigated. An optical imaging technique was also employed to capture similar dynamic events in comparison with the radiographic imaging. It is demonstrated that high-speed X-ray PCI had sufficient phase contrast to characterize a crack initiation at a 20-μm spatial resolution within 920 ns and track the crack geometry during propagation, thereby providing reliable data to quantify the dynamic damage resistance of GFRCs. Furthermore, being capable of recognizing microscopic damage-related features at a sub-10-μm resolution, high-speed X-ray PCI provided fundamental material failure mechanisms to reveal the essential of macroscale structural failure of composites. It can also track the damage evolution inside and between individual plies of laminated composites. However, current high-speed X-ray PCI technique only supports in-situ observation and the high timing and spatial resolutions are limited within a field of view of ~2.5 mm in square, preventing its application in the three-dimensional and larger-area damage detection for GFRC structures.

42 ENGINEERING↗

Two-temperature model in molecular dynamics simulations of cascades in Ni-based alloys

In high-energy irradiation events, energy from the fast moving ion is transferred to the system via nuclear and electronic energy loss mechanisms. The nuclear energy loss results in the creation of point defects and clusters, while the energy transferred to the electrons results in the creation of high electronic temperatures, which can affect the damage evolution. We perform molecular dynamics simulations of 30 keV and 50 keV Ni ion cascades in nickel-based alloys without and with the electronic effects taken into account. We compare the results of classical molecular dynamics (MD) simulations, where the electronic effects are ignored, with results from simulations that include the electronic stopping only, as well as simulations where both the electronic stopping and the electron-phonon coupling are incorporated, as described by the two temperature model (2T-MD). Our results indicate that the 2T-MD leads to a smaller amount of damage, more isolated defects and smaller defect clusters.

Zarkadoula, Eva↗

Spall fracture in additive manufactured Ti-6Al-4V

Here, we present a study on the spall strength of additive manufactured (AM) Ti-6Al-4V. Samples were obtained from two pieces of selective laser melted (SLM, a powder bed fusion technique) Ti-6Al-4V such that the response to dynamic tensile loading could be investigated as a function of the orientation between the build layers and the loading direction. A sample of wrought bar-stock Ti-6Al-4V was also tested to act as a baseline representing the traditionally manufactured material response. A single-stage light gas-gun was used to launch a thin flyer plate into the samples, generating a region of intense tensile stress on a plane normal to the impact direction. The rear free surface velocity time history of each sample was recorded with laser-based velocimetry to allow the spall strength to be calculated. The samples were also soft recovered to enable post-mortem characterization of the spall damage evolution. Results showed that when the tensile load was applied normal to the interfaces between the build layers caused by the SLM fabrication process the spall strength was drastically reduced, dropping to 60% of that of the wrought material. However, when loaded parallel to the AM build layer interfaces the spall strength was found to remain at 95% of the wrought control, suggesting that when loading normal to the AM layer interfaces, void nucleation is facilitated more readily due to weaknesses along these boundaries. Quasi-static testing of the same sample orientations revealed a much lower degree of anisotropy, demonstrating the importance of rate-dependent studies for damage evolution in AM materials.

36 MATERIALS SCIENCE↗

Poster and Slide: Energy Loss: Exploring Dissipation Pathways from Ions to In-reactor

Young Researcher Association is hosting an early career poster and networking session on July 25th, 2019. The poster session is designed to provide an overview of the researcher’s experience prior to employment at INL, and their current area of research and interests. The following is a brief description of the major sections of the poster. Before starting at INL in May of this year, my research focused on exploring the effects of electronic and nuclear energy loss on the damage evolution of Ti3SiC2 MAX phase during energetic irradiations. A series of ion irradiations revealed a threshold in electronic energy loss (Se), above which the formation of a FCC-MAX structure is enhanced, accommodating point defects and alleviating lattice strain. However, systematically separating the effects reveals that increasing Se/Sn suppresses this phase formation, thus allowing the strain from point defects to increase and saturate. Presently my research supports Post Irradiation Examination (PIE) of U-Mo fuel for the USHPRR and KJRR programs. The PIE evaluation currently consists of non-destructive examination (NDE) of fuel plates irradiated in the Advanced Test Reactor (ATR), focusing on plate profilometry and fuel swelling analysis. NDE will culminate in finalizing the destructive examination (DE) test plans and execution of said DE. Additionally, I am interested in exploring the roles that different energy dissipation pathways play in the damage evolution of the U-Mo fuel, exploring the mechanisms by which the fuel remains in its meta-stable phase under irradiation at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗