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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Material and component developments for the DEMO divertor using fibre reinforcement and additive manufacturing

Within the research along the European Fusion Roadmap, water-cooled divertor PFCs are foreseen in the design of a first fusion demonstration power plant (DEMO) in order to provide reliable heat removal capability. In the frame of this concerted attempt, the Max Planck Institute for Plasma Physics is concentrating on the development and testing of composite materials based on tungsten (W, preferred armour material) and copper (Cu, preferred heat sink material). W fibres (W f ) as monofilaments and yarns as reinforcement play a central role in these investigations due to their extraordinary properties concerning ductility already at room temperature and high tensile strength. Recent investigations on the impact of radiation damage suggest that the fibres retain their ductility upon irradiation. W reinforced with W fibres (W f /W) allows to overcome the intrinsic brittleness of W. Quantitative mechanical fracture tests of W f /W confirm the basic mechanisms of fibre reinforcement and the increased resistance to mechanical fatigue. The good wettability of W with liquid Cu and the absence of any metallurgical solubility make up an ideal material pairing for composite production. W fibre-reinforced Cu (W f /Cu) cooling tubes provide a rather high thermal conductivity (> 250 W mK -1 ) and at least twice the strength of CuCrZr in hoop direction in the temperature range up to at least 500 °C. Very recent neutron irradiation experiments confirm the sustainment of ductility of the W f /Cu composite. Numerical simulations suggest that thermal stresses in W-Cu PFCs could be strongly reduced by tailoring the local W and Cu volume fraction. This 'freely' distributed material composition can be achieved by means of additively manufactured W skeletons consecutively infiltrated by Cu. Investigations with W preforms produced by Laser Beam Powder Bed Fusion and infiltrated by Cu demonstrate the feasibility of this approach while testing of specifically prepared specimen is ongoing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Controlling dendrite propagation in solid-state batteries with engineered stress

Metal-dendrite penetration is a mode of electrolyte failure that threatens the viability of metal-anode-based solid-state batteries. Whether dendrites are driven by mechanical failure or electrochemical degradation of solid electrolytes remains an open question. If internal mechanical forces drive failure, superimposing a compressive load that counters internal stress may mitigate dendrite penetration. Here, we investigate this hypothesis by dynamically applying mechanical loads to growing dendrites in Li 6.6 La 3 Zr 1.6 Ta 0.4 O 12 solid electrolytes. Operando microscopy reveals marked deflection in the dendrite growth trajectory at the onset of compressive loading. For sufficient loading, this deflection averts cell failure. Using fracture mechanics, we quantify the impact of stack pressure and in-plane stresses on dendrite trajectory, chart the residual stresses required to prevent short-circuit failure, and propose design approaches to achieve such stresses. For the materials studied here, we show that dendrite propagation is dictated by electrolyte fracture, with electronic leakage playing a negligible role.

25 ENERGY STORAGE↗
DOE OSTI2023

Microseismic Monitoring of Laboratory Hydraulic Fracturing Experiments in Granitic Rocks for Different Fracture Propagation Regimes

While hydraulic fracturing (HF) is a widely employed process, the underlying fracturing processes are still heavily contested. The attributes of the HF generated fracture network can exhibit substantial variation when dealing with specific HF propagation regimes encountered in the field. In this study, HF experiments were performed on true-triaxially loaded Barre granite cubes, with microseismic monitoring, to identify and characterize the fracturing mechanisms associated with different viscosity injection fluids. Utilizing fluids with high (oil/1450 cP) and low (water/1 cP) viscosity represented two key HF propagation regimes: viscosity- and toughness-dominated. The experiments conducted with oil involved higher breakdown pressures, larger fluid volumes, and slower fracture propagation speeds. Furthermore, the frequency–magnitude distribution (b value) for all experiments (1.9–2.3) was similar to those encountered for large-scale operations. Slightly larger b values were encountered during the initiation phase (2.4–2.7) relative to the fracture propagation and post-fracturing phases (1.9–2.2). Techniques such as polarity and moment-tensor inversion were utilized to characterize the source mechanisms. For the HF experiments with oil, tensile fractures were most dominant (92%) in the initiation phase compared to fracture propagation and post-fracturing phases (70–75%). Similar tensile fracturing dominancy was not observed with water, attributable to fluid permeation and leak-off. Regardless of the injection fluid or classification criteria employed, tensile fractures were the dominant type consistently, with fewer occurring in water experiments but the specific ratio of crack types varied with different source mechanism criteria employed.

58 GEOSCIENCES↗
DOE OSTI2020

Molecular scale insight of pore morphology relation with mechanical properties of amorphous silica using ReaxFF

Porous materials are typically heterogeneous and they contain large variations of micro-/nano-pore structures, causing complicated behaviors. In continuum models, most mechanical properties of porous materials are estimated based on porosity, while the variations of micro/nano structures are ignored. That could be problematic as the microscopic heterogeneity may affect the mechanical response of porous materials. Thus, understanding micro/nano heterogeneity impact has been the focus in many scientific and engineering subjects. In the present study, we investigated the effect of nanopore structure (including pore shape and orientation) as well as porosity on mechanical properties of amorphous silica (a-SiO 2 ). The pore sizes in our simulations are comparable to the corresponding ones observed in a-SiO 2 based materials. We found that the existing of nanopores strongly influences Young’s modulus (E) and critical energy release rate (G IC ). These properties decrease with increasing porosity. Importantly, the impact of nanopores was characterized by structural parameters of porous materials. In addition to dependency on porosity, Young’s modulus also was found to vary as a function of potential energy per atom, which highly depends on nanopore shape. Furthermore, critical energy release rate was found to increase with increasing ligament length (also known as pore wall thickness). Finally, the results highlighted the importance of nanopore structures, which must be taken into account when studying fracture mechanisms in porous materials. Based on our findings, it was proposed that mechanical properties of porous materials can be controlled by nano-engineering pore structures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Flaw-insensitive fracture of a micrometer-sized brittle metallic glass

Brittle materials, such as oxide glasses, are usually very sensitive to flaws, giving rise to a macroscopic fracture strength that is much lower than that predicted by theory. The same applies to metallic glasses (MGs), with the important difference that these glasses can exhibit certain plastic strain prior to catastrophic failure. Here we consider the strongest metallic alloy known, a ternary Co 55 Ta10B 35 MG. In this work, we show that this macroscopically brittle glass is flaw-insensitive at the micrometer scale. This discovery emerges when testing pre-cracked specimens with self-similar geometries, where the fracture stress does not decrease with increasing pre-crack size. The fracture toughness of this ultra-strong glassy alloy is further shown to increase with increasing sample size. Both these findings deviate from our classical understanding of fracture mechanics, and are attributed to a transition from toughness-controlled to strength-controlled fracture below a critical sample size.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Statistical mechanical model for crack growth

Analytic relations that describe crack growth are vital for modeling experiments and building a theoretical understanding of fracture. Upon constructing an idealized model system for the crack and applying the principles of statistical thermodynamics, it is possible to formulate the rate of thermally activated crack growth as a function of load, but the result is analytically intractable. In this report an asymptotically correct theory is used to obtain analytic approximations of the crack growth rate from the fundamental theoretical formulation. These crack growth rate relations are compared to those that exist in the literature and are validated with respect to Monte Carlo calculations and experiments. The success of this approach is encouraging for future modeling endeavors that might consider more complicated fracture mechanisms, such as inhomogeneity or a reactive environment.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Energy Release Rate Approximation for Small Surface Cracks in Three-Dimensional Domains Using the Topological Derivative

The topological derivative describes the variation of a response functional with respect to infinitesimal changes in topology, such as the introduction of an infinitesimal crack or hole. In this three-dimensional fracture mechanics work, we propose an approximation of the energy release rate field associated with a small surface crack of any boundary location, direction, and orientation combination using the topological derivative. Furthermore, this work builds on the work of Silva et al. (“Energy Release Rate Approximation for Small Surface-Breaking Cracks Using the Topological Derivative,” J. Mech. Phys. Solids 59(5), pp. 925–939), in which the authors proposed an approximation of the energy release rate field which was limited to two-dimensional domains. The proposed method is computationally advantageous because it only requires a single analysis. By contrast, current boundary element and finite element-based methods require an analysis for each crack length-location-direction-orientation combination. Furthermore, the proposed method is evaluated on the non-cracked domain, obviating the need for refined meshes in the crack tip region.

42 ENGINEERING↗
DOE OSTI2021

Investigation of hardening mechanisms and size effects in proton-irradiated HT-9 steels

Ferritic/martensitic steels, such as HT-9, are known for their complex microstructural features and mechanical properties. Here in this paper, in-situ micro-tensile tests and traditional fractography methods were utilized to study the fracture behavior of proton-irradiated HT-9 steels. First, to evaluate the viability of micro-tensile tests for nuclear material qualification process, meso-tensile tests on as-received HT-9 steels were performed. Fracture mechanisms of unirradiated HT-9 steels at both length scales were compared and underlying mechanisms discussed. The direct comparison of micro- and meso-scale data shows a distinctive size effect demonstrated by the increase in yield stress (YS). Upon completion of initial assessment, specimens were irradiated with 4 MeV + protons to three fluences, all of which were lower than 0.01 displacements per atom (dpa). As expected, the YS increases with irradiation. However, at 7 × 10 -3 dpa, the reversal of the trend was observed, and the YS exhibited sharp decline. We demonstrate that at lower length scales, grain structure has a more profound impact on the mechanical properties of irradiated materials, which provides information needed to fill in the gap in current understanding of the HT-9 fracture at different length scales.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Irradiation-assisted Stress Corrosion Cracking of PWRirradiated Type 347 Stainless Steel (NSUF CINR 19-16567)

This document serves as the final report for NSUF Project 19-16567 (Reference 1) and its supporting contracts (References 2 and 3). It documents completion of testing of specimens fabricated as previously described in Reference 4. At a high level, the purpose of the testing is to generate data to support continued operation of light water reactors (LWR) and provide further understanding of irradiation-assisted stress corrosion crack (IASCC) initiation in baffle-former bolt materials. Baffle-former bolts that had been extracted from commercial pressurized water reactors (PWRs) were machined into miniature 4-point bend specimens and TEM samples at the Westinghouse Churchill Site hot cell facility. These samples were then shipped to the University of Michigan to undergo IASCC initiation testing in simulated PWR primary coolant containing either LiOH or KOH additions. Overall, 15 samples were tested, 8 in water with KOH additions and 7 in water with LiOH additions, until indications of cracking were observed. Crack initiation stress was similar in both water environments at 50-60% of the irradiated yield stress. Post-test examination of the cracking sites, including scanning electron microscopy and transmission electron microscopy, demonstrated that the crack initiation mechanism and crack initiation rates were similar between the two different water chemistries. A grain boundary oxidation and oxide fracture mechanism was observed to be responsible for crack initiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Directly Probing the Fracture Behavior of Ultrathin Polymeric Films

Understanding fracture mechanics of ultrathin polymeric films is crucial for modern technologies, including semiconductor and coating industries. However, up to now, the fracture behavior of sub-100 nm polymeric thin films is rarely explored due to challenges in handling samples and limited testing methods available. In this work, we report a new testing methodology that can not only visualize the evolution of the local stress distribution through wrinkling patterns and crack propagation during the deformation of ultrathin films but also directly measure their fracture energies. Using ultrathin polystyrene films as a model system, we both experimentally and computationally investigate the effect of the film thickness and molecular weight on their fracture behavior, both of which show a ductile-to-brittle transition. Furthermore, we demonstrate the broad applicability of this testing method in semicrystalline semiconducting polymers. We anticipate our methodology described here could provide new ways of studying the fracture behavior of ultrathin films under confinement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

HELPR Version 1.1.0 User Guide

Hydrogen Extremely Low Probability of Rupture (HELPR) is a modular probabilistic fracture mechanics modeling platform developed to assess structural integrity of pipelines for transmission and distribution of hydrogen. HELPR couples fatigue and fracture engineering models with probabilistic methods to generate fast predictions and enables quantification of prediction uncertainty and sensitivity. This user manual serves as a guide through the various analysis features HELPR contains.

08 HYDROGEN↗
DOE OSTI2022

Micromechanics of Fracture Propagation During Multistage Stress Relaxation and Creep in Brittle Rocks

Time-dependent rock deformation caused by the initiation and growth of fractures leads to the weakening of the rock mass. Understanding the fracturing mechanisms involved in the time-dependent behavior in brittle rocks is very important and to achieve this goal, a systematic series of three types of experiments was performed on double-flawed prismatic Barre granite specimens under unconfined compression. The first series aimed to identify the failure mechanism in the short-term failure mode under monotonic loading, the, second series involved multistage relaxation (constant strain) experiments to analyze the damage at different strain levels, and the third series explored the fracture propagation under multistage creep (constant load) experiments. The spatial and temporal evolution of cracking mechanisms were evaluated using the acoustic emission (AE) and two-dimensional digital image correlation (2D-DIC) techniques to observe the whole crack growth process as well as the accumulated inelastic strain at the specified region of interest. Results suggest that in the case of multistage creep experiments, the time to failure was less compared to the multistage relaxation, when loaded above the crack damage threshold (CD) estimated from the monotonic testing. Furthermore, the frequency magnitude distribution of the AE events generated in the three loading conditions followed the Gutenberg Richter model. A relatively lower b-value was obtained for the creep experiments, indicative of high energy AE events and faster crack growth. In addition, the AE and DIC results also revealed high evolution of tensile cracks at-different stages of creep and relaxation compared to shear and mixed-mode cracks.

58 GEOSCIENCES↗
DOE OSTI2020

Fractal breakage of porous carbonate sand particles: Microstructures and mechanisms

In situ, three-dimensional (3D) characterizations of particle breakage in porous carbonate sands are presented, for the first time, with synchrotron-based micro computed tomography. Evolution of grain-scale characteristics are identified and quantified via elaborate image processing and topology analyses. The sequential 3D images reveal distinctly different fracture mechanisms for carbonate sands from silica sands. The angular shape of carbonate sand particles facilitates bending fracture, and particles with a lower sphericity and a higher porosity are more prone to break. 3D crack networks extracted from fractured particles imply considerable cleavage along initial pores. The fractal dimension of crack networks increases with external loading due to crack branching via cleavage. The resultant fragment size distribution also appears fractal and the fractal feature is valid down to the breakage limit of calcium carbonate. Crack propagation along the initial pores reduces the energy barrier for particle breakage and thus fracture strength of particles

Carbonate sands↗
DOE OSTI2024

Microstructural Engineering and Accelerated Test Method Development to Achieve Low Cost, High Performance Solutions for Hydrogen Storage and Delivery

This project made advancements in developing lower cost steel alloys with novel microstructural design for use in hydrogen refueling infrastructure such as storage, compressors, and dispensing components, and utilizing accelerated test methods to efficiently evaluate variations in alloy and microstructure design. The project specifically sought to design alloys with lower nickel contents to reduce alloy cost, which was accomplished through substituting manganese for nickel along with other alloy additions to control deformation characteristics known to be important for hydrogen embrittlement resistance. Through Mn substitutions for nickel, austenitic and duplex austenite-ferrite steels were successfully developed with lower cost than currently available commercial stainless steel products that are employed for hydrogen refueling infrastructure. The steels were processed to achieve comparable strength and toughness in hydrogen environments as the commercially available steels containing high Ni contents. To evaluate mechanical performance in hydrogen, a testing methodology was employed to compare ubiquitous laboratory testing using electrochemical hydrogen charging in a liquid electrolyte to less accessible high pressure gaseous testing. While the application of these steels is in high pressure gaseous environments, the electrochemical hydrogen charging tests produced comparable results. Additionally, the Los Alamos Neutron Scatting Center enabled characterization of deformation mechanisms of the steel alloys in the presence of hydrogen, which has been associated with steel alloy characteristics associated with hydrogen embrittlement. Finally, a fracture mechanics based test bed model was developed to predict the influence of hydrogen gas pressure and fatigue conditions on fatigue lifetimes of pressure vessel steels. Together, these developments can be employed to enable lower cost hydrogen fueling infrastructure and more reliable prediction of steel alloy components in hydrogen service conditions. In particular, the newly alloys have the potential to replace stainless steels, having demonstrated comparable performance at substantially reduced cost.

08 HYDROGEN↗
DOE OSTI2025

Morphological Heterogeneity Impact of Film Solid-State Cathode on Utilization and Fracture Dynamics

Structural heterogeneity in solid-state batteries can impact material utilization and fracture mechanisms. Crystallographically oriented lithium cobalt oxide film cathodes serve as a model electrode system for exploring how void distribution contributes to stress relief and build up during cycling. Real- and reciprocal-space operando and ex situ synchrotron based experiments are utilized to understand structural changes across multiple length scales contribute to stress generation and fracture. Nanotomography uncovers a depth-dependent porosity variation in the pristine electrode and highlights preferential fracture in regions of lower porosity during delithiation. Energy-dispersive X-ray diffraction and 3D X-ray absorption near-edge spectroscopy (XANES) reveal the underutilization of cathode material in these regions. 3D XANES also confirms preferential delithiation near the sub-grain boundaries. Chemo-mechanical modeling coupled with site-specific mechanical characterization demonstrate how stress accumulation in dense regions of the electrode leads to fracture and underutilization of active material. In conclusion, our findings reveal the importance of materials design to alleviate stress in small-volume changing cathodes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The Sealing Mechanisms of a Fracture in Opalinus Clay as Revealed by in situ Synchrotron X-Ray Micro-Tomography

The detailed mechanisms of the sealing of a single fracture, from hydration to almost complete closure by increase of confining pressure, as monitored from in situ synchrotron X-ray microtomography during the flow of carbonated water, is here shown for the first time. Different mechanisms play the key role at different stages in the evolution of the fracture. Hydration mechanically weakens the surfaces of the fracture and induces a first closure due to microcracking at the asperity contacts, increasing their size and creating choke points. Increase in confining stress promptly hydraulically seals the fracture by closing the main choke point, with a relative small deformation of the sample. Finally, the more pervasive mechanical deformation observed at higher stresses almost completely seals the whole fracture. The evolution of the sample has been described and quantified using 4D image processing, focusing on the evolution of aperture and digital volume correlation. Hydraulic properties of the sample at different stages have been modeled via Stokes flow simulation, and the results compared to the morphometric analysis, finding positive correlations with the average fracture aperture variation along the flowpath in function of confining pressure. Opalinus Clay is found to be a rock markedly prone to sealing in case of flow with carbonated water; this behavior is the result of the large fraction of clays and of its microstructure, lacking both cementing phases and large stiff particles. CO2 in this sample has no evident role in the evolution of the fracture; chemically induced weathering on the surface has not been detected, in contrast with the behavior observed in samples with carbonates as cementing phase.

58 GEOSCIENCES↗
DOE OSTI2025

Micromechanical response of SiC-OPyC layers in TRISO fuel particles

Tristructural isotropic (TRISO)–coated particle fuel is a proposed fuel for multiple advanced reactor concepts. The performance of the particle depends on whether the silicon carbide (SiC) layer remains intact to prevent the release of metallic and gaseous fission products. Mechanical fracture of the SiC layer is a potential failure mode under various fuel configurations and operating environments, including the potential transmission of matrix-originating cracks through TRISO particles. Furthermore, this study uses instrumented indentation techniques on cross-sectioned surrogate particles to examine the mechanical stability of the critical interface between SiC and the outer pyrolytic carbon (OPyC) layer. The observed behavior at the interface is rationalized by examining the radially dependent fracture behavior of the SiC layer and performing a numerical analysis to quantify the residual stresses that develop during the processing and cross-sectioning of the as-fabricated particle. Characterizing the SiC-OPyC interface of surrogate TRISO particles using nanoindentation provides unique insight into the interface's room-temperature residual stress and mechanical stability. The modeling efforts were used to investigate the experimental procedure further, and the results are presented herein to validate this fuel form's potential mechanical failure modes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

DECOVALEX-2023: Task G, SAFENET Final Report

DECOVALEX Task G deals with fracture mechanics at several scales using a combined approach of experimental work, related model development, benchmarking and experimental analysis. Fig. 0.1 provides a graphical abstract for Task G. The experimental basis for the related mechanical (M), hydro-mechanical (HM), and thermo-mechanical (TM) processes comes from the rock mechanics laboratories of Universities of Freiberg (TUBAF) and Edinburgh, as well as the Korea Institute of Civil Engineering and Building Technology (KICT). The experimental work in the rock laboratories is closely linked to the underground research laboratories (URLs) Reiche Zeche (Germany), KURT (Korea), and Mont Terri (Switzerland). The scientific key questions are related to fracture permeability evolution under THM conditions, anisotropy effects on fracturing processes, and thermal fracture slip, which are being addressed in specific steps of the task. A large variety of numerical methods have been developed and applied for experimental analysis, ranging from continuum to discontinuum approaches. A detailed comparison of mechanical and hydro-mechanical processes is given in the section 3 via the benchmarking exercises. As a result of DECOVALEX-2023 Task G we further improved our understanding and predictability of fracturing processes under THM conditions. This was based on robust numerical simulation methods and in-depth experimental analysis.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗