The calculation of elevated temperature cyclic life considering low cycle fatigue and creep
Cyclic life calculations of materials sujected to isothermal stress considering fatigue and creep
Spera, D. A.↗
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Fracture Analysis of ARB-Processed CP-Ti Sheets Under Unidirectional Tensile Loading
The fracture behavior of commercially pure titanium (CP-Ti) processed by accumulative roll bonding (ARB) was investigated in this study. Monolithic and Ti-SiC composite samples were first produced by ARB process and then subjected to uniaxial tensile testing at room temperature. Two different ductile fracture mechanisms including shear dimple rupture and equiaxed dimple rupture were observed in the initial and final ARB cycles, respectively. The difference in the rupture mechanism was attributed to different stress states at the crack tip and different densities of metallurgical defects. A non-uniform distribution of dimple size was obtained for fracture surfaces of the samples processed by a low number of ARB cycles. This was attributed to the heterogeneity of microstructure in the primary ARB cycles. The fracture surface of the samples processed by high ARB cycles represented more uniform dimples. This was attributed to more homogenous microstructure in the final cycles. Moreover, SiC particles showed a major role in fracture of samples, so that they affected the size and depth of the dimples, as well as the number of ARB cycles in which the transmission of the fracture mechanism occurred.
36 MATERIALS SCIENCE↗
Fatigue characterization of advanced carbon-carbon composites
Response of quasi-isotropic laminates of SiC coated Carbon-Carbon (C/C) composites under flexural fatigue are investigated at room temperature. Virgin as well as mission cycled specimens are tested to study the effects of thermal and pressure cycling on the fatigue performance of C/C. Tests were conducted in three point bending with a stress ratio of 0.2 and frequency of 1 Hz. Fatigue strength of C/C has been found to be considerably high - approximately above 85 percent of the ultimate flexural strength. The fatigue strength appears to be decreasing with the increase in the number of mission cycling of the specimens. This lower strength with the mission cycled specimens is attributed to the loss of interfacial bond strength due to thermal and pressure cycling of the material. C/C is also found to be highly sensitive to the applied stress level during cyclic loading, and this sensitivity is observed to increase with the mission cycling. Weibull characterization on the fatigue data has been performed, and the wide scatter in the Weibull distribution is discussed. Fractured as well as untested specimens were C-scanned, and the progressive damage growth during fatigue is presented.
Mahfuz, Hassan↗
Single-cell RNA sequencing reveals intrinsic and extrinsic regulatory heterogeneity in yeast responding to stress
From bacteria to humans, individual cells within isogenic populations can show significant variation in stress tolerance, but the nature of this heterogeneity is not clear. To investigate this, we used single-cell RNA sequencing to quantify transcript heterogeneity in single Saccharomyces cerevisiae cells treated with and without salt stress to explore population variation and identify cellular covariates that influence the stress-responsive transcriptome. Leveraging the extensive knowledge of yeast transcriptional regulation, we uncovered significant regulatory variation in individual yeast cells, both before and after stress. Moreover, we discovered that a subset of cells appears to decouple expression of ribosomal protein genes from the environmental stress response in a manner partly correlated with the cell cycle but unrelated to the yeast ultradian metabolic cycle. Live-cell imaging of cells expressing pairs of fluorescent regulators, including the transcription factor Msn2 with Dot6, Sfp1, or MAP kinase Hog1, revealed both coordinated and decoupled nucleocytoplasmic shuttling. Together with transcriptomic analysis, our results suggest that cells maintain a cellular filter against decoupled bursts of transcription factor activation but mount a stress response upon coordinated regulation, even in a subset of unstressed cells.
59 BASIC BIOLOGICAL SCIENCES↗
Mechanical and Thermal Properties of Two Cu-Cr-Nb Alloys and NARloy-Z
A series of creep tests were conducted on Cu-8 Cr-4 Nb (Cu-8 at.% Cr-4 at.% Nb), Cu-4 Cr-2 Nb (Cu-4 at.% Cr-2 at% Nb), and NARloy-Z (Cu-3 wt.% Ag-0.5 wt.% Zr) samples to determine their creep properties. In addition, a limited number of low cycle fatigue and thermal conductivity tests were conducted. The Cu-Cr-Nb alloys showed a clear advantage in creep life and sustainable load over the currently used NARloy-Z. Increases in life at a given stress were between 100% and 250% greater for the Cu-Cr-Nb alloys depending on the stress and temperature. For a given life, the Cu-Cr-Nb alloys could support a stress between 60% and 160% greater than NARloy-Z. Low cycle fatigue lives of the Cu-8 Cr-4 Nb alloy were equivalent to NARloy-Z at room temperature. At elevated temperatures (538 C and 650 C), the fatigue lives were 50% to 200% longer than NARloy-Z samples tested at 538 C. The thermal conductivities of the Cu-Cr-Nb alloys remained high, but were lower than NARloy-Z and pure Cu. The Cu-Cr-Nb thermal conductivities were between 72% and 96% that of pure Cu with the Cu-4 Cr-2 Nb alloy having a significant advantage in thermal conductivity over Cu-8 Cr4 Nb. In comparison, stainless steels with equivalent strengths would have thermal conductivities less than 25% the thermal conductivity of pure Cu. The combined results indicate that the Cu-Cr-Nb alloys offer an attractive alternative to current high temperature Cu-based alloys such as NARloy-Z.
Ellis, David L.↗
Failure Analysis for Molten Salt Thermal Energy Storage Tanks for In-Service CSP Plants
Thermal Energy Storage (TES) is a fundamental component in concentrating solar power (CSP) plants to increase the plant's dispatchability, capacity factor, while reducing the levelized cost of electricity. In central receivers CSP plants, nitrate molten salts have been used for several years for operation temperatures of up to 565 degrees C. Despite many efforts to advance nitrate salt to higher operation temperatures (even considering a replacement with molten chloride salts) to achieve higher energy conversion efficiencies, the 565 degrees C temperature is currently considered the state-of-the art. Although molten salt tanks have been broadly deployed in commercial CSP plants worldwide, several failures have been reported in these tanks after a few months or years of operation, causing significant economic loss and mistrust in CSP technologies. Most of these failures are associated with the infancy of the technology and multiple issues related to tank design, fabrication, commissioning, and aggressive operation. A technical standard dedicated to the design and fabrication of molten nitrate TES tanks does not exist today. Current in-service molten salt tanks have been generally designed based on the American Petroleum Institute's (API) 650 and ASME Section II standards. The API 650 code provides guidelines for dimensions and fabrication for oil storage tanks up to 260 degrees C. The ASME standard provides allowable stress values for various materials at a range of temperatures and conditions. Both standards seem to be limited for molten salt TES tanks where high temperatures, thermal cycling, and transient conditions are expected. In 2020, NREL released the Concentrating Solar Power Best Practices Study (NREL/TP-5500-75763) that summarized multiple issues in CSP plants, along with potential alternatives and recommendations to address those issues based on information collected from participants representing about 80% of operating CSP plants in the world. One of the recommendations from this study was the development of accurate and validated models to evaluate the plant's transient operation, capable of capturing the effect of short-term clouds and operator response, while being flexible in being adapted to various spatial and temporal resource data. The "Failure Analysis for Molten Salt Thermal Energy Tanks for In-Service CSP Plants" project was inspired on this recommendation and was focused on (1) the development and validation of a physics-based model for a representative, commercial-scale molten salt tank, (2) performing simulations to evaluate the behavior of the tank as a function of typical plant operation conditions, (3) understanding tank failures mechanisms, (4) determining the residual stress and distortion in the tank floor after welding fabrication and evaluating their impact in the stresses developed in the tank during operation, (5) assessing the impact of key operation parameters on the temperature and stress distribution, (6) conduct a preliminary evaluation of design features to reduce stress and improve tank's reliability, and (7) estimate the tank's service life based on the stress developed under diverse operation scenarios. From the analysis conducted in the project and presented in this report, it was found that maximum stresses surpassing the yield strength point of the stainless steel (SS) 347H are developed on the tank floor near the perimeter. These large stresses are strongly influenced by the initial residual stresses and distortion of the tank floor after welding fabrication. During operation, large stresses are developed in the tank floor at high operation temperatures with large salt inventory levels during transient operation. High stresses are also related to elevated temperature gradients in the tank floor that could be attributed to insufficient mixing within the salt inflow and the salt inventory. Based on the analysis, creep is the predominant failure mechanism. However, the large stress levels could favor the plastic deformation into buckles, and crack formation due to stress relaxation cracking during cycle operation. A lifetime below 3 years was estimated for the typical plant operation conditions and a specific initial residual stress and deformation distribution of the tank floor. The estimated life agrees with the service time to failure reported in several commercial molten salt tanks. Desing and operation guidelines can be extracted from the analysis presented in this report, which could be adopted by tank manufacturers and CSP operators to advance toward an ultimate solution for tank failures by reducing residual and operational stresses to achieve a tank service life of more than 30 years. Addressing failures in molten salt TES tanks is fundamental for the CSP industry's survivability, but it is also important for other industrial and power generation applications using this technology, including nuclear and concentrating solar thermal.
14 SOLAR ENERGY↗
Prognostics Approach for Power MOSFET Under Thermal-Stress
The prognostic technique for a power MOSFET presented in this paper is based on accelerated aging of MOSFET IRF520Npbf in a TO-220 package. The methodology utilizes thermal and power cycling to accelerate the life of the devices. The major failure mechanism for the stress conditions is dieattachment degradation, typical for discrete devices with leadfree solder die attachment. It has been determined that dieattach degradation results in an increase in ON-state resistance due to its dependence on junction temperature. Increasing resistance, thus, can be used as a precursor of failure for the die-attach failure mechanism under thermal stress. A feature based on normalized ON-resistance is computed from in-situ measurements of the electro-thermal response. An Extended Kalman filter is used as a model-based prognostics techniques based on the Bayesian tracking framework. The proposed prognostics technique reports on preliminary work that serves as a case study on the prediction of remaining life of power MOSFETs and builds upon the work presented in [1]. The algorithm considered in this study had been used as prognostics algorithm in different applications and is regarded as suitable candidate for component level prognostics. This work attempts to further the validation of such algorithm by presenting it with real degradation data including measurements from real sensors, which include all the complications (noise, bias, etc.) that are regularly not captured on simulated degradation data. The algorithm is developed and tested on the accelerated aging test timescale. In real world operation, the timescale of the degradation process and therefore the RUL predictions will be considerable larger. It is hypothesized that even though the timescale will be larger, it remains constant through the degradation process and the algorithm and model would still apply under the slower degradation process. By using accelerated aging data with actual device measurements and real sensors (no simulated behavior), we are attempting to assess how such algorithm behaves under realistic conditions.
Power MOSFET PHM↗
Hygrothermal damage mechanisms in graphite-epoxy composites
T300/5209 and T300/5208 graphite epoxy laminates were studied experimentally and analytically in order to: (1) determine the coupling between applied stress, internal residual stress, and moisture sorption kinetics; (2) examine the microscopic damage mechanisms due to hygrothermal cycling; (3) evaluate the effect of absorbed moisture and hygrothermal cycling on inplane shear response; (4) determine the permanent loss of interfacial bond strength after moisture absorption and drying; and (5) evaluate the three dimensional stress state in laminates under a combination of hygroscopic, thermal, and mechanical loads. Specimens were conditioned to equilibrium moisture content under steady exposure to 55% or 95% RH at 70 C or 93 C. Some specimens were tested subsequent to moisture conditioning and 100 cycles between -54 C and either 70 C or 93 C.
Crossman, F. W.↗
Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings
To improve gas turbine and diesel engine performance using thermal barrier coatings (TBC's) requires an understanding of the factors that influence the in-service behavior of thermal barrier coatings. One of the many factors related to coating performance is the state of stress in the coating. The total stress state is composed of the stresses due to the in-service loading history and the residual stresses. Residual stresses have been shown to affect TBC life, the bond strength of thermal spray coatings, and the fatigue life of tungsten carbide coatings. Residual stresses are first introduced in TBC's by the spraying process due to elevated temperatures during processing and the difference in coefficients of thermal expansion of the top coat, bond coat, and substrate. Later, the residual stresses can be changed by the in-service temperature history due to a number of time and temperature dependent mechanisms, such as oxidation, creep, and sintering. Silica content has also been shown to affect sintering and the cyclic life of thermal barrier coatings. Thus, it is important to understand how the spraying process, the in-service thermal cycles, and the silica content can create and alter residual stresses in thermal barrier coatings.
McGrann, Roy T. R.↗
Investigation of forming curved ablative panels from flat panels for space shuttle
The purpose of this study was to determine the feasibility of reforming flat ablative panels to a curved configuration. The study indicated that if the panels could be shaped to a radius of 2.54 m (100 in.) then 88.7% of the surface area of the orbiter could be covered, and that if they could be shaped to a radius of 3.81 m (150 in.) then 77.2% of the surface could be covered. Two basic approaches were followed to determine the best method for forming the flat panels to a curved shape. The first was to determine if partially cured panels could be formed, allowing the forming heat cycle to complete the curing of the ablator. The second method was to form fully cured flat panels into the desired curvature through a secondary heat cycle. Measurements made on the panels during storage indicated that they continued to straighten out over time. This was attributed to residual stresses locked into the panels that had not been fully relaxed by the heat cycle.
Chandler, H. H.↗
In situ SEM thermal fatigue of Al/graphite metal matrix composites
Several thermal fatigue-induced failure mechanisms are deduced for unidirectional graphite-reinforced 6061 Al-alloy MMCs subjected to in situ thermal cycling. These thermal cycling conditions are representative of MMC service cycles in aerospace environments, where thermal fatigue is primarily associated with changes in the stress states near the interfaces due to coefficient of thermal expansion mismatch between fiber and matrix. This in situ SEM thermal-cycling study clarified such factors affecting MMCs' thermal fatigue as local fiber content and distribution, void volume, fiber stiffness, thermal excursion magnitude, and number of thermal cycles. MMC microfailure modes in thermal fatigue have been deduced.
Zong, G. S.↗
Exploring the Interaction Between Head-Supported Mass, Posture, and Visual Stress on Neck Muscle Activation
Objective Assess neck muscle activity for varying interactions between helmet, posture, and visual stress in a simulated “helo-hunch” posture. Background Military aviators frequently report neck pain (NP). Risk factors for NP include head-supported mass, awkward postures, and mental workload. Interactions between these factors could induce constant low-level muscle activation during helicopter flight and better explain instances of NP. Method Interactions between physical loading (helmet doffed/donned), posture (symmetric/asymmetric), and visual stress (low/high contrast) were studied through neck muscle electromyography (EMG), head kinematics, subjective discomfort, perceived workload, and task performance. Subjects ( n = 16) performed eight 30-min test conditions (varied physical loading, posture, and visual stress) while performing a simple task in a simulated “helo-hunch” seating environment. Results Conditions with a helmet donned had fewer EMG median frequency cycles (which infer motor unit rotation for rest/recovery, where more cycles are better) in the left cervical extensor and left sternocleidomastoid. Asymmetric posture (to the right) resulted in higher normalized EMG activity in the right cervical extensor and left sternocleidomastoid and resulted in less lateral bending compared with neutral across all conditions. Conditions with high visual stress also resulted in fewer EMG cycles in the right cervical extensor. Conclusion A complex interaction exists between the physical load of the helmet, postural stress from awkward postures, and visual stress within a simulated “helo-hunch” seating environment. Application These results provide insight into how visual factors influence biomechanical loading. Such insights may assist future studies in designing short-term administrative controls and long-term engineering controls.
Behavioral Sciences↗
Gravitational effects of process-induced dislocations in silicon
Matters pertaining to semiconductor device fabrication were studied in terms of the influence of gravity on the production of dislocations in silicon wafers during thermal cycling in a controlled ambient where no impurities are present and oxidation is minimal. Both n-type and p-type silicon wafers having a diameter of 1.25 in to 1.5 in, with fixed orientation and resistivity values, were used. The surface dislocation densities were measured quantitatively by the Sirtl etch technique. The results show two significant features of the plastic flow phenomenon as it is related to gravitational stress: (1) the density of dislocations generated during a given thermal cycle is directly related to the duration of the cycle; and (2) the duration of the thermal cycle required to produce a given dislocation density is inversely related to the equilibrium temperature. Analysis of the results indicates that gravitational stress is instrumental in process-induced defect generation.
Porter, W. A.↗
Unified Analysis of Aerospace Structures through Implementation of Rapid Tools into a Stress Framework
Rapid structural analysis tools have become an important part of the design cycle for aerospace companies for the last several decades. As these tools have been developed over time, there is often little consideration for shared software infrastructure between the tools, which makes design and analysis cumbersome due to a lack of commonality in input and output data and reporting, as well as poor traceability of results. Under the Rapid Tools task of the Advanced Composites Consortium (ACC), four aerospace tools were recently implemented or enhanced in the HyperSizer stress framework and then evaluated by this consortium of industry and government organizations. The framework provides an automated software environment for executing the rapid tools for analysis and sizing, quantifying margins of safety for thousands of load cases, and generating reports in support of FAA certification. This paper describes the process by which the tools were enhanced or implemented in the stress framework under the ACC project, and the evaluation conducted by industry consortium members.
Craig S Collier↗
Mathematical Modeling in Systems for Operational Evaluation of the Stress-Strain State of the Arch-Gravity Dam at the Sayano-Shushenskaya Hydroelectric Power Plant
Current studies of the stress-strain state of the dam at the Sayano-Shushenskaya Hydroelectric Power Plant at VNIIG based on mathematical modeling including full scale and experimental data are described. Applications and programs intended for automatic operational evaluation of the stress-strain state of the dam for optimizing control of the upper race level in the course of the annual filling-drawdown cycle and during seismic events are examined. Improvements in systems for monitoring the stress-strain state of concrete dams are proposed.
42 ENGINEERING↗
Relation of Engine Turbine-blade Life to Stress-rupture Properties of the Alloys, Stellite 21, Hastelloy B, Cast S-816, Forged S-816, X-40, Nimonic 80, Refractaloy 26, N-155, and Inconel X
An investigation was conducted to relate the engine performance of the heat-resistant alloys, Stellite 21, Hastelloy B, cast S-816, forged S-816, X-40, Nimonic 80, Refractory 26, N-155, and Iconel X to their stress-rupture properties. The engine test consisted of the repetition of a 20-minute cycle, 15 minutes at rated speed and approximately 5 minutes at idle. The results of the investigation indicated a direct correlation between stress-rupture life and blade life for the relatively low-strength alloys. The stress-rupture life and blade life for the relatively high-strength alloys did not correlate because of the effects of the vibratory stresses and the corrosive-gas atmosphere.
ALLOYS, HEAT-RESISTING↗
Solar cycle variations of the solar wind
Throughout the course of the past one and a half solar cycles, solar wind parameters measured near the ecliptic plane at 1 AU varied in the following way: speed and proton temperature have maxima during the declining phase and minima at solar minimum and are approximately anti-correlated with number density and electron temperature, while magnetic field magnitude and relative abundance of helium roughly follow the sunspot cycle. These variations are described in terms of the solar cycle variations of coronal holes, streamers, and transients. The solar wind signatures of the three features are discussed in turn, with special emphasis on the signature of transients, which is still in the process of being defined. It is proposed that magnetic clouds be identified with helium abundance enhancements and that they form the head of a transient surrounded by streamer like plasma, with an optional shock front. It is stressed that relative values of a parameter through a solar cycle should be compared beginning with the declining phase, especially in the case of magnetic field magnitude.
Crooker, N. U.↗
Variation of crack-opening stresses in three-dimensions - Finite thickness plate
A 3D elastic-plastic finite-element analysis is conducted to study crack-growth behavior of thin and thick center-cracked specimens under constant-amplitude loading conditions. The numerical analysis and the specimen configuration and loading are described for both the thin and thick conditions. Stabilized crack-opening stresses of interior and exterior regions are given as are the closure and opening profiles of the crack-surface plane after the tenth cycle. The effect of thickness is discussed with respect to the crack-opening stress levels and the plastic zones of the interior and exterior regions. A load-reduced-displacement technique allows the calculation of the crack-opening stresses at three locations on the crack surface plane. The constraint effect related to thickness gives a lower stabilized crack-opening stress level for the thick specimens.
Chermahini, R. G.↗