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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 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Studies on Ti, Zn and Ti + Zn Bilayer Coatings on Interstitial Free Steel for Enhancement of Wear and Corrosion Resistance

The present study concerns a detailed investigation of the microstructure, phase identity, composition, residual stress, wear and corrosion behavior of Ti, Zn and Zn + Ti coatings developed on IF steel by sputter deposition technique. A significant improvement in average microhardness (350-700 VHN) is noticed following sputter deposition compared to that of as-received IF steel (190 VHN). The highest microhardness recorded is 500 VHN for Ti, 350 VHN for Zn and 700 VHN for Ti + Zn bilayer, respectively. Improvement in surface hardness is accompanied by a marked improvement in wear resistance of the sputter-deposited surface against hardened steel ball. The corrosion rate of coated sample in 3.56 wt.% NaCl solution is marginally decreased (2.95 × 10{sup −2} to 3.25 × 10{sup −2} mm/year) as compared to that of as-received IF steel (3.55 × 10{sup −2} mm/year). Ti-deposited IF steel registers the minimum corrosion rate (2.95 × 10{sup −2} mm/year) among all the coated samples.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Improving the Strength of the ZrC-SiC and TC4 Brazed Joint Through Fabricating Graded Double-Layered Composite Structure on TC4 Surface

In order to improve the ZrC-SiC ceramic and TC4 brazed joint property, graded double-layered SiC particles (SiCp)-reinforced TC4-based composite structure (named as GLS for convenience) was designed to relieve the residual stress in the joint. The GLS was successfully fabricated on TC4 substrate by double-layered laser deposition technology before the brazing process. The investigation of the GLS shows that the volume fraction of SiCp in the two composite layers was graded (20 and 39 vol pct, respectively). Ti{sub 5}Si{sub 3} and TiC phases formed in the GLS due to the reaction of SiCp and TC4. The laser power-II (the laser power for the second deposition layer) affected the microstructure of the GLS significantly. Increasing the laser power-II would promote the reaction between the SiCp and TC4. But the high laser power-II made the layer I remelt completely and the two layers became homogeneous rather than graded structure. In the ZrC-SiC and TC4 brazed joint, the CTE (coefficient of thermal expansion) was graded from the TC4 to the ZrC-SiC due to the GLS, and the strength of the joint with the GLS (91 MPa) was higher than that without the GLS (43 MPa).

36 MATERIALS SCIENCE↗
DOE OSTI2020

Towards improved speed and accuracy of laser powder bed fusion simulations via multiscale spatial representations

Due to the growing popularity of laser powder bed fusion (LPBF) as a metal additive manufacturing technique, there is a strong need to be able to accurately predict build outcomes. Full fidelity simulations of this process are not feasible due to the vast range of length and time scales inherent to it. While part-scale codes for simulating residual stress and distortion have shown reasonable predictive capability, they often neglect many aspects of the process occurring over smaller length/time scales, and thus are unable to capture effects of process parameter adjustments or the behavior of fine features. One way of capturing aspects at more refined length scales is through the use of adaptive mesh refinement (AMR). AMR allows for the process to be simulated at scales approaching the physical spatial dimensions without drastically increasing the total degrees of freedom in the simulation. This manuscript describes the implementation of an AMR algorithm within a multiphysics, parallelized finite element code, and its application to the LPBF problem. In this work, part-scale examples are provided where the use of AMR has allowed for higher fidelity thermal and thermomechanical simulations, as compared to experimental measurements. Results from these higher resolution simulations show that while AMR is a necessary component for increased accuracy in a computationally efficient manner, other improvements are also necessary, including handling of the multiple time scales inherent to the problem and the need for improved AM-specific material models.

42 ENGINEERING↗
DOE OSTI2019

Computational Simulation of an Additively Manufactured Marine Component

Early work in finite-element analysis of additive manufacturing (AM) components was not able to include distortion and residual stress of the entire build, yielding uncertainty in the computational model predictions. To address this, current versions of recently developed computational tools are being used to understand their role in validation at the Naval Surface Warfare Center, Carderock Division, for laser powder-bed fusion (L-PBF) AM. A 316L stainless steel L-PBF build containing multiple parts, which exhibited the same local part failure over multiple AM fabrication runs, was selected for computational analysis. Single-part simulations analyzed optimization of computational speed and prediction accuracy. Full-build simulations exposed the smallest re-coater tolerances early in part fabrication as a result of part shrinkage and subsequent cupping. This cupping was predicted to change the powder spreading and result in the non-consolidation of the support structures, which paralleled the failures seen in the physical builds. Part redesign of the conventionally produced part to align with AM fabrication requirements was recommended to alleviate the build failures. This project is part of a larger program focused on validation of the computational tools to determine best practices for insertion of AM simulation into the greater Naval enterprise.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Correcting distortions of thin-walled machined parts by machine hammer peening

Thin-walled aerostructural components frequently get distorted after the machining process. Reworking to correct distortions or eventually rejecting parts significantly increases the cost. This paper proposes a new approach to correct distortions in thin-walled components by strategically applying hammer peening on target surfaces of a machined component. Aluminium alloy 7475-T7351 was chosen for this research. The study was divided in two stages. First, the residual stresses (RS) induced by four different pneumatic hammer peening conditions (modifying the stepover distance and initial offset) were characterised in a test coupon, and one of the conditions was selected for the next stage. In the second stage, a FEM model was used to predict distortions caused by machining in a representative workpiece. Then, the RS induced by hammer peening were included in an FEM model to define two hammer peening strategies (varying the coverage area) to analyse the capability to reduce distortions. Two workpieces were machined and then treated with the simulated hammer peening strategies for experimental validation. Results in the test coupon showed that pneumatic hammer peening can generate high compressive RS (-50 to –350 MPa) up to 800 μm depth, with their magnitude increasing with a reduced stepover distance. Application of hammer peening over 4% of the surface of the representative workpiece reduced the machining-induced distortions by 37%, and a coverage area of 100% led to and overcorrection by a factor of five. This confirms that hammer peening can be strategically applied (in target areas and changing the percentage of coverage) to correct low or severe distortions.

42 ENGINEERING↗
DOE OSTI2020

Effect of heat treatment on microstructural evolution and hardness homogeneity in laser powder bed fusion of alloy 718

The thermal history developed in laser powder bed fusion (LPBF) processes has been shown to be complex resulting in equally complex microstructures and mechanical properties. Microscopic observations and Vickers micro-hardness mapping measurements were carried out on diff ;erent section planes of LPBF alloy 718 cuboids. Three-dimensional finite element analysis was used to simulate thermal history and to predict the residual stress distribution in the as-built material. Computational thermodynamics was used to predict the micro-segregation and nucleation driving force of various phases in the bulk and in segregated regions. Varied heat-treatments such as simulated hot isostatic pressing, and double aging were applied. Their influence on the microstructure, microsegregation, precipitate formation, and micro-hardness variations of LPBF alloy 718 were investigated. Hardness map results showed heterogeneous micro-hardness on the xy- and xz-planes of the as-built parts where the bottom plane and center regions had larger hardness of ~315 HV 0.5 while the top plane and contours showed hardness of ~300 HV 0.5 . It was found that the aging treatment increased the overall hardness of the as-built condition from ~310 HV 0.5 to 470 HV 0.5 but also increased the hardness gradient throughout the coupon. After simulated hot isostatic pressing process (i.e., without applied pressure) at 1020 °C for 4 h followed by water quench (HIPWQ), the hardness gradient and hardness was minimized (~210 HV 0.5 ) as the microstructure transitioned from heterogeneous columnar grains in the as-built condition to more uniform recrystallized grains. A double aging treatment was applied to enhance hardness from ~210 HV 0.5 to ~440 HV 0.5 . Finally, HIPWQ followed by double aging produced a homogeneous microstructure and more uniform hardness map with enhanced mechanical properties in LPBF alloy 718 coupons.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Slow Strain Rate Testing of A537 Tank Wall Material

At Savannah River Site (SRS), High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion and/or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate will increase, while the hydroxide and nitrite concentration of the interstitial liquid will deplete and become insufficient to prevent the onset of corrosion attack. Tank blending and the addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite. However, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processing. This testing program was designed to examine the risk of SCC associated with utilizing the pitting factor (PF) and nitrite/nitrate (NO 2 - /NO 3 - ) ratio limits for handling dissolved salt solutions at an elevated temperature in the carbon steel waste tanks. The previously identified limits are a PF of 1.2 and an NO 2 - /NO 3 - ratio of 0.15. The results indicate that as long as the NO 2 - /NO 3 - ratio exceeds 0.1 and the PF is above approximately 0.8, there is a discernible safety margin between the open circuit potential (OCP) and the critical cracking potential (CCP) observed during applied potential testing. However, this margin, defined by the difference between the OCP and CCP, is relatively narrow, ranging from 0.1 to 0.25 volts. This small margin raises concerns about potential shifts in OCP during waste retrieval operations, which could inadvertently increase the risk of SCC if the OCP approaches or exceeds the CCP. These results confirm that dissolved salt solutions provide a potent chemistry that, under certain conditions, makes carbon steel susceptible to SCC. The next question to consider is the influence these results have on decisions for storage and retrieval of waste from the tanks. For Type III/IIIA waste tanks, the risk of SCC remains very low. First, and most importantly, the post-weld stress relief of the tanks has reduced the residual stress near the welds. Thus, without the stress component, SCC risk is minimized. The material of construction (A537 Carbon steel) for the Type III/IIIA tanks is superior to the steel in its resistance to SCC than the steel that was utilized for the Type I, II, and IV tanks (A285 carbon steel). From a chemistry control standpoint for a Type III/IIIA tank directly involved with handling dissolved salt solutions, the PF and NO 2 - /NO 3 - ratio limits may be utilized wherein chemistry control provides an extra layer of defense against SCC. Chemistry control for a Type III/IIIA tank minimizes the risk for a tank that may receive the dissolved salt solution, particularly if that tank is a Type I, II, or IV waste tank. On the other hand, if the dissolved salt solution is handled by a Type I, II, or IV waste tank the risk of SCC is real. The potent chemistry, absence of stress relief, and inferior material result in a condition that is conducive to cracking. Efforts should be made to either avoid transferring waste that may not meet the PF and NO 2 - /NO 3 - ratio criteria to one of these tanks or if it is unavoidable, take measures to minimize the consequences of a leak. As shown by these tests, even if the PF and NO 2 - /NO 3 - ratio criteria are met, there is a risk that the tank potential may be disturbed in the positive direction and the risk of SCC increase.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1981

Boundary layer thermal stresses in angle-ply composite laminates, part 1

Thermal boundary-layer stresses (near free edges) and displacements were determined by a an eigenfunction expansion technique and the establishment of an appropriate particular solution. Current solutions in the region away from the singular domain (free edge) are found to be excellent agreement with existing approximate numerical results. As the edge is approached, the singular term controls the near field behavior of the boundary layer. Results are presented for cases of various angle-ply graphite/epoxy laminates with (theta/-theta/theta/theta) configurations. These results show high interlaminar (through-the-thickness) stresses. Thermal boundary-layer thicknesses of different composite systems are determined by examining the strain energy density distribution in composites. It is shown that the boundary-layer thickness depends on the degree of anisotropy of each individual lamina, thermomechanical properties of each ply, and the relative thickness of adjacent layers. The interlaminar thermal stresses are compressive with increasing temperature. The corresponding residual stresses are tensile and may enhance interply delaminations.

Wang, S. S.↗
NASA NTRS1982

Ultrasonic measurement of axial stress

The theory of acoustic propagation in strained media is examined, with particular emphasis on rod (bolt) geometries. The continuous wave (CW) approach is the basis of the study, and the theory is developed from a frequency domain analysis standpoint in order to obtain an applied stress/normalized frequency shift relationship. CW measurements may be influenced by such factors as propagation effects, mode conversion, frequency, material properties, and geometry. After the first loading cycle, axial stress measurements for a preloading with an initial frequency of 4.995 36 MHz dropped to 4.989 19 MHz, indicating a 6.17 kHz change. CW and pseudo-CW ultrasonic techniques are found to be reliable for axial stress measurements, and acoustic attenuation measurements correlated to residual stress fields may possibly involve transducer phase cancellation. It is thus concluded that signal drop is an artifact of the transducer directivity, rather than an actual acoustic power decrease.

Heyman, J. S.↗
NASA NTRS1985

Measurement and analysis of critical crack tip processes during fatigue crack growth

The mechanics of fatigue crack growth under constant-amplitudes and variable-amplitude loading were examined. Critical loading histories involving relatively simple overload and overload/underload cycles were studied to provide a basic understanding of the underlying physical processes controlling crack growth. The material used for this study was 7091-T7E69, a powder metallurgy aluminum alloy. Local crack-tip parameters were measured at various times before, during, and after the overloads, these include crack-tip opening loads and displacements, and crack-tip strain fields. The latter were useed, in combination with the materials cyclic and monotonic stress-strain properties, to compute crack-tip residual stresses. The experimental results are also compared with analytical predictions obtained using the FAST-2 computer code. The sensitivity of the analytical model to constant-amplitude fatigue crack growth rate properties and to through-thickness constrain are studied.

Davidson, D. L.↗
NASA NTRS1985

Nonlinear structural analysis for fiber-reinforced superalloy turbine blades

A computational capability for predicting the nonlinear thermomechanical structural response of fiber-reinforced superalloy (FRS) turbine blades is described. This capability is embedded in a special purpose computer code (COBSTRAN) developed at the NASA Lewis Research Center. Special features of this computational capability include accounting for: fiber/matrix reaction, nonlinear and anisotropic material behavior, complex stress distribution due to local and global heterogeneity, and residual stresses due to initial fabrication and/or inelastic behavior during subsequent missions. Numerical results are presented from analyses of a hypothetical FRS turbine blade subjected to a fabrication process and subsequent mission cycle. The results demonstrate the capabilities of this computational tool to; predict local stress/strain response and capture trends of local nonlinear and anisotropic material behavior, relate the effects of this local behavior to the global response of a multilayered fiber-composite turbine blade, and trace material history from fabrication through successive missions.

Hopkins, D. A.↗
NASA NTRS1999

Quantification of Processing Effects on Filament Wound Pressure Vessels

A computational simulation procedure is described which is designed specifically for the modeling and analysis of filament wound pressure vessels. Cylindrical vessels with spherical or elliptical end caps can be generated automatically. End caps other than spherical or elliptical may be modeled by varying circular sections along the x-axis according to the C C! end cap shape. The finite element model generated is composed of plate type quadrilateral shell elements on the entire vessel surface. This computational procedure can also be sued to generate grid, connectivity and material cards (bulk data) for component parts of a larger model. These bulk data are assigned to a user designated file for finite element structural/stress analysis of composite pressure vessels. The procedure accommodates filament would pressure vessels of all types of shells-of-revolution. It has provisions to readily evaluate initial stresses due to pretension in the winding filaments and residual stresses due to cure temperature.

Aiello, Robert A.↗
NASA NTRS2002

Quantification of Processing Effects on Filament Wound Pressure Vessels

A computational simulation procedure is described which is designed specifically for the modeling and analysis of filament wound pressure vessels. Cylindrical vessels with spherical or elliptical end caps can be generated automatically. End caps other than spherical or elliptical may be modeled by varying circular sections along the x-axis according to the end cap shape. The finite element model generated is composed of plate type quadrilateral shell elements on the entire vessel surface. This computational procedure can also be used to generate grid, connectivity and material cards (bulk data) for component parts of a larger model. These bulk data are assigned to a user designated file for finite element structural/stress analysis of composite pressure vessels. The procedure accommodates filament wound pressure vessels of all types of shells-of -revolution. It has provisions to readily evaluate initial stresses due to pretension in the winding filaments and residual stresses due to cure temperature.

Aiello, Robert A.↗
DOE OSTI2025

A stress-sensitive precipitate nucleation model beyond classical nucleation theory

The dynamic evolution of precipitates and second phases dictates the strength and stability of most engineering alloys. By design, or as a consequence of thermo-mechanical aging, engineering metals and alloys often form precipitates of second phases when subjecting to diverse thermal and mechanical loads. Precipitation is governed by several factors, including the alloy’s composition, processing/operating temperature, and stresses — either as a result of external loads or from residual stresses. However, state-of-the-art models for precipitate nucleation (i.e., classical nucleation theory) typically lacks consistent method to capture the effects of externally applied and/or internal stresses on nucleation; thereby severely limiting the applicability of these models to complex materials systems and to representative loading scenarios. Here, in this work, we extend upon classical nucleation theory to account for the effect of stresses on precipitation kinetics and thermodynamics. This is achieved via the use of an Eshelbian micromechanics framework keeping track of (i) the stress build up resulting from second phase formation as a function of mechanical load and, (ii) the effects of dislocations on precipitate formation. This new model is applied to σ precipitate in Fe–Cr binary alloys and M 23 C 6 precipitate in 316H stainless steel (SS). Simulations demonstrate the important role of both the remotely applied loads and dislocation pile ups on precipitate nucleation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Inelastic Deformation in Methylammonium Lead Iodide Perovskite and Mitigation by Additives during Thermal Cycling

Metal halide perovskite thin films are promising materials for next-generation photovoltaic applications, but the thermomechanical instabilities of these materials are critical barriers to device longevity. In this study, we measure the evolution of stresses in methylammonium lead iodide (MAPbI3) films thermally cycled from 25 to 105 °C using a multibeam optical stress sensor (MOSS) system. We demonstrate that these films undergo residual stress buildup due to inelastic deformation as well as a simple mitigation strategy by incorporating low concentrations of 5-aminovaleric acid hydrochloride (5-AVACl) as an additive. Adding 5-AVACl increases the tensile stresses measured at room temperature but beneficially decreases the biaxial modulus from 9.60 ± 0.44 GPa to 7.95 ± 0.55 GPa, resulting in greater accommodation of thermal stresses. The hysteresis loop is ~63% smaller with the inclusion of 5-AVACl, and the stress relaxation at 50 °C decreases from 86.46 to 51.49 MPa. The larger stress relaxation in pristine MAPbI 3 is correlated with grain boundary opening after five cycles, while the inclusion of 5-AVACl mitigates this degradation. Furthermore, our findings underscore the importance of studying the dynamic response of perovskite films during thermal cycling and lay the foundation for further exploration into the mechanisms governing the thermomechanical behavior of perovskite thin films.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Role of Amorphous Chains in Nanoplastic Formation from Semicrystalline Polymers

Semicrystalline polymers, e.g., polyethylene terephthalate (PET), release micro- (100 nm to 1 mm) and nanoplastics (up to 100 nm) [MNPL] when they are degraded under quiescent conditions. However, the exact molecular mechanisms leading to material fragmentation into MNPL are unknown. Here, we monitor the evolution of chain molecular weight and the MNPL production kinetics during hydrolysis of PET pellets. We find that only ~0.6% of the amorphous phase ester bonds are hydrolyzed at the onset of MNPL release. Then, by combining a random scission model with measured amorphous spacings, we estimate that only ~15% of the stress transmitters in the amorphous phase, namely, bridges and entangled loops, have failed by this point. Thus, spontaneous fragmentation of the semicrystalline nanostructure occurs despite significant intercrystalline connectivity. We resolve this apparent contradiction by proposing that fragmentation can only occur when progressive tie-chain scission causes the material to undergo the ductile/brittle transition. Mechanistically, we speculate that the internal stresses responsible for material fragmentation are caused by processing (i.e., residual stresses) and/or sample densification induced by chemi-crystallization. We discuss additional factors that may affect our analysis and thus require further investigation, such as skin-core effects, preferential degradation of stress transmitters and/or recrystallization processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1967

Miniature stress transducer Patent

Miniature solid state, direction sensitive, stress transducer design with bonded semiconductive piezoresistive element for sensing residual stresses

San Miguel, A.↗
NASA NTRS1974

High-tip-speed fiber composite compressor blades: Vibration and strength analysis

An analytical procedure is described which couples composite mechanics computer codes with NASTRAN. This procedure was used to perform a detailed analysis of a high-tip-speed fiber composite compressor fan blade. The results indicate that the various vibration modes of this blade are highly coupled. Mechanical load ply stresses are well below the corresponding room temperature strengths. Lamination residual stresses are likely to cause transply cracks and interply delamination. Transply cracks and relaxation of root fixity decrease the vibrational frequencies whereas centrifugal stiffening increases them. Comparisons of results for various parameters are presented in tabular and graphical form.

Chamis, C. C.↗