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NASA NTRS1952

A Theoretical and Experimental Investigation of the Influence of Temperature Gradients on the Deformation and Burst Speeds of Rotating Disks

The purposes of this investigation were to evaluate the influence of temperature gradients and to test the validity of a recently developed method of calculating plastic flow in disks by comparing the calculated results with experimental observations. Short-time spin tests on parallel-sided, 10-inch-diameter disks were conducted under conditions that subject the disks to a range of temperatures from 70 to 1440 F. The agreement between the theoretical and experimental results was good over the range of temperature conditions investigated. Temperature gradients produced little reduction in the burst speed of the disks which had a high ductility..

LOADS AND STRESSES, STRUCTURAL↗

DOE OSTI2021

Gradient cell–structured high-entropy alloy with exceptional strength and ductility

We report that similar to conventional materials, most multicomponent high-entropy alloys (HEAs) lose ductility as they gain strength. In this study, we controllably introduced gradient nanoscaled dislocation cell structures in a stable single-phase HEA with face-centered cubic structure, thus resulting in enhanced strength without apparent loss of ductility. Upon application of strain, the sample-level structural gradient induces progressive formation of a high density of tiny stacking faults (SFs) and twins, nucleating from abundant low-angle dislocation cells. Furthermore, the SF-induced plasticity and the resultant refined structures, coupled with intensively accumulated dislocations, contribute to plasticity, increased strength, and work hardening. These findings offer a promising paradigm for tailoring properties with gradient dislocation cells at the nanoscale and advance our fundamental understanding of the intrinsic deformation behavior of HEAs.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Quantitative characterization of gradient microstructures: A study on friction stir spot processing of pure cobalt

Heterogeneous microstructures in polycrystalline metals can enhance the strength and ductility, outperforming homogeneous structures of similar composition. This study investigates deformed cobalt via friction stir spot processing with varying dwell times to uncover the effects of plastic deformation and heat generation on the formation of morphological, phase, and grain boundary character gradients. A new approach to quantify the morphological gradients in materials, which describes grain morphology in terms of density followed by parametric regression, enables direct quantification of processing depth and gradient sharpness. Results show that longer processing times increase the steepness of morphological gradients and reduce the deformation depth for friction stir spot processing with low plunge depths and high tool rotational speeds. The amount of retained FCC is increased in the shorter processing conditions, primarily due to refined grain size, increased defect content, and reduced heat generation. Crystallographic texture analysis of the HCP phase indicated a dominant B-fiber described by (0001) ∥ shear plane normal in the extreme processing conditions and the formation of a P-fiber, shear direction ∥ ⟨11$\bar2$0⟩ for intermediate dwell times. The texture of the FCC phase for low processing times was a C texture {100}⟨011⟩ where longer processing times were dominated by a [001] fiber texture with a main {110}⟨100⟩ orientation and emergence of a slight [111] fiber in the longest processing condition. The approaches outlined in this work give insight into quantifying gradients and improve the understanding of highly deformed cobalt.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Residual Stress in Cold Spray SS304L Measured Via Neutron Diffraction and Comparison of Analytical Models to Predict the Residual Stress

Here, this study employs neutron diffraction to investigate the relationship between residual stress and coating thickness in cold sprayed 304L austenitic stainless steel. Results show that shot peening predominantly impacts the residual stress profile, leading to substantial in-plane compressive force. The impact of laser heating, a widely used method to alter cold spray's microstructural properties, on the coating's residual stress is also analyzed. The findings indicate that the maximum compressive residual stress in the in-plane component is mainly independent of coating thickness, which suggests that the material properties determine the maximum residual stress. The cold sprayed deposits possessed compressive, nearly biaxial strain and stresses. After laser heating, these stresses were replaced by tensile residual stresses. Two analytical models, the Tsui and Clyne and the Boruah models, for predicting residual stresses are also evaluated, and both models provide reasonable fits to the experimental data. At this point, the deviations between the experimental results and the models are principally caused by the inability of the current models to address plastic deformation and relaxation, and the residual stresses generated by thermal gradients.

36 MATERIALS SCIENCE↗

DOE OSTI2025

One Step Block-like Copolymers from an Upcycled Monomer Using Ring-Opening Metathesis Polymerization

Block-like copolymers can be readily synthesized in one step using monomers with widely separated reactivity ratios. Here, we show that trans,trans,trans-1,5,9-cyclododecatriene (CDT), produced from polybutadiene via cyclodepolymerization (CDP), undergoes gradient copolymerization via ring-opening metathesis polymerization (ROMP) with a selected norbornene monomer to produce a block-like copolymer that exhibits bulk nanophase separation and excellent thermomechanical performance. These data highlight a new ROMP copolymerization system with a sharp compositional drift and introduce a simple pathway to convert waste plastic into a valuable building block for high-value thermoplastic materials.

block copolymer↗

DOE OSTI2020

Characterization of precipitation in gradient Inconel 718 superalloy

Inconel 718 (IN718) superalloy is a well-established material for the application of aircraft engine and power generator due to its excellent performance at high temperatures. The outstanding mechanical properties of IN718 are largely determined by the precipitates. Here, we investigated the precipitation behaviors and the corresponding mechanical properties of the heat-treated gradient IN718 alloy. The microscopy studies reveal that high-density hexagonal η phase with chemistry of Ni 3 (Al,Ti,Nb) formed in the nanograined IN718 alloy after annealing at 700 °C. Additionally, the compressive stress introduced during severe plastic deformation may have prohibited the formation of γ” phase while accelerated the precipitation of γ’ phase, consequently favoring the precipitation of η phase. The corresponding evolution of mechanical behavior of gradient IN718 alloy is investigated.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Response tailoring of elasto-plastic trusses

Abstract In this work we tailor the response of trusses loaded beyond their yield limit. The truss structures are modeled using finite strain theory and rate-independent elasto-plasticity. We design trusses with a tailored mechanical response that is between “elastic” and “elastic-ideal-plastic” subject to the volume constraint. The design updates are generated by the gradient-based Method of Moving Asymptotes (MMA) solver and the sensitivities of the response functions are computed using a path-dependent adjoint sensitivity analysis. The computations are performed in Matlab.

42 ENGINEERING↗

DOE OSTI2021

Crack tip microplasticity mediated by microstructure gradients

Abstract Traditional fracture theories infer damage at cracks (local field) by surveying loading conditions away from cracks (far field). This approach has been successful in predicting ductile fracture, but it normally assumes isotropic and homogeneous materials. However, myriads of manufacturing procedures induce heterogeneous microstructural gradients that can affect the accuracy of traditional fracture models. This work presents a microstructure‐sensitive finite element approach to explore the shielding effects of grain size and crystallographic orientation gradients on crack tip microplasticity and blunting. A dislocation density‐based crystal plasticity model conveys texture evolution, grain size effects, and directional hardening by computing the constraint from dislocation structures. The results demonstrate that the microstructure can act as a buffer between the local and far fields that affects the crack tip microplasticity variability. For nominal opening loading, grain size and texture affect the local ductility and induce a non‐negligible multiaxial plastic deformation. Furthermore, driving forces based on measuring displacements away from the crack tip are less affected by the microstructure, which suggests that traditional experimental methods smear out important crack tip variability.

Castelluccio, Gustavo M.↗

DOE OSTI2024

Salt Tank Testbed: a Test Site Designed to Replicate Floor Buckles Observed in Commercial TES Tanks

A test site has been designed and is under construction to replicate the buckling failure ob-served in several in-service storage tanks for nitrate salts operating up to 565°C. In commercial tanks multiple factors have been identified that influence the floors susceptibility to buck-ling, including: the as-manufactured shape of the floor, high compressive stresses due to thermal gradients and/or friction, fluid inventory and absolute temperature. Based on exten-sive modeling analysis it was determined that similar buckles can be reproduced in a scaled test tank (approximately 9x smaller than a representative commercial tank design). To buckle the scaled tank a radial thermal gradient is generated in the tank with a low fluid level, the fluid level is then increased while maintaining the thermal gradient; based on the modeling results just one of these cycles can plastically deform the tank floor. The test site which is under construction is designed to replicate this damaging cycle at lower temperatures. The goal of testing will be to reproduce this damaging cycle and buckle the scaled test tank floor, allowing proper model validation and a methodology for comparing different tank designs at a smaller (and less costly) scale.

25 ENERGY STORAGE↗

NASA NTRS1975

Research and development of low cost processes for integrated solar arrays

Si reduction, purification and sheet generation work has been concentrated on gaining information about a reduction process combined with purification (higher purity arc furnace with gas blowing and gradient freezing), transport process with purification and polycrystal sheet growth potential (SiF2), plastic deformation for sheet generation, and float zone sheet recrystallization.

Wolf, M.↗

NASA NTRS1990

Thermal/structural analyses of several hydrogen-cooled leading-edge concepts for hypersonic flight vehicles

The aerodynamic heating at high flight Mach numbers, when shock interference heating is included, can be extremely high and can exceed the capability of most conventional metallic and potential ceramic materials available. Numerical analyses of the heat transfer and thermal stresses are performed on three actively cooled leading-edge geometries (models) made of three different materials to address the issue of survivability in a hostile environment. These analyses show a mixture of results from one configuration to the next. Results for each configuration are presented and discussed. Combinations of enhanced internal film coefficients and high material thermal conductivity of copper and tungsten are predicted to maintain the maximum wall temperature for each concept within acceptable operating limits. The exception is the TD nickel material which is predicted to melt for most cases. The wide range of internal impingement film coefficients (based on correlations) for these conditions can lead to a significant uncertainty in expected leading-edge wall temperatures. The equivalent plastic strain, inherent in each configuration which results from the high thermal gradients, indicates a need for further cyclic analysis to determine component life.

Gladden, Herbert J.↗

NASA NTRS1990

Thermal/structural analyses of several hydrogen-cooled leading-edge concepts for hypersonic flight vehicles

Gladden, Herbert J.↗

DOE OSTI2020

Analysis of structure-property gradients in orthogonally machined chips and workpiece subsurface

Production of machined surfaces with optimized mechanical properties requires fundamental process-structure-property knowledge. In this paper, we focus on structure-property gradients in orthogonally cut OFHC Copper chips and the workpiece subsurface. We utilize orientation imaging microscopy and statistical spatial correlation metrics to quantify the microstructure. Constitutive elastic-plastic properties of the workpiece subsurface and chips are measured using spherical nanoindentation. Analysis of the data reveals significant structure and property gradients in both regions. Differences and similarities in structure and property gradients near the workpiece surface and tool-chip interface, and in the chip middle are discussed and explained.

42 ENGINEERING↗

NASA NTRS2009

Computer Code for Nanostructure Simulation

Due to their small size, nanostructures can have stress and thermal gradients that are larger than any macroscopic analogue. These gradients can lead to specific regions that are susceptible to failure via processes such as plastic deformation by dislocation emission, chemical debonding, and interfacial alloying. A program has been developed that rigorously simulates and predicts optoelectronic properties of nanostructures of virtually any geometrical complexity and material composition. It can be used in simulations of energy level structure, wave functions, density of states of spatially configured phonon-coupled electrons, excitons in quantum dots, quantum rings, quantum ring complexes, and more. The code can be used to calculate stress distributions and thermal transport properties for a variety of nanostructures and interfaces, transport and scattering at nanoscale interfaces and surfaces under various stress states, and alloy compositional gradients. The code allows users to perform modeling of charge transport processes through quantum-dot (QD) arrays as functions of inter-dot distance, array order versus disorder, QD orientation, shape, size, and chemical composition for applications in photovoltaics and physical properties of QD-based biochemical sensors. The code can be used to study the hot exciton formation/relation dynamics in arrays of QDs of different shapes and sizes at different temperatures. It also can be used to understand the relation among the deposition parameters and inherent stresses, strain deformation, heat flow, and failure of nanostructures.

Filikhin, Igor↗

DOE OSTI2025

Localized orientation gradients in additively manufactured stainless steel 316H structures

The high solidification rates during additive manufacturing cause highly localized thermal and strain gradients. The effect of these gradients on the evolution of local orientation misorientations within a grain is not well understood. In this study, stainless steel 316H parts were fabricated via laser powder bed fusion using three different energy densities: 43, 71, and 135 J/mm 3 . Electron backscatter diffraction showed that the maximum misorientations of the grains can be up to 25° along the build direction. Misorientation gradients (RM g ) within grains are process-dependent and can change from 0.036°/μm to 0.015°/μm with increased volumetric energy densities. In conclusion, the characterized misorientation gradients are an indication of the level of dislocations and, to an extent, the plastic deformation resulting from the rapid solidification during laser powder bed fusion.

316H↗

DOE OSTI2025

Micro-structural features and material properties impact on adhesive metal joints via computational modeling and machine learning

The quality of structural bonding in practical applications depends on various factors arising from materials, pre-processing conditions, and manufacturing. Understanding how these factors influence bonding performance and determining their relative importance are of significant interest. Thus, this study evaluates the effects of microstructural features and material properties on the structural strength of adhesively-bonded metal joints at the submillimeter scale, utilizing a combination of Finite Element Modeling (FEM) and Machine Learning (ML) with Gradient Boosting Regression (GBR). The microstructural features include adhesive thickness, internal voids within the adhesive, adherend-adhesive interfacial voids, void size and volume fraction, and surface roughness. The material properties include the constitutive behavior of the adhesive, as well as the adherend-adhesive interfacial strength and fracture energy. The changes in structural strength and morphologies of the bonded metal structures with respect to different microstructural features and material properties were clarified by FEM. By further leveraging ML-GBR, the sequence of importance of these factors affecting bonding performance across various scenarios was summarized. This work provides valuable insights into the development of improved structural bonding for adhesive joints in industries such as automotive , aerospace, and beyond.

36 MATERIALS SCIENCE↗

NASA NTRS1990

Materials with periodic internal structure: Computation based on homogenization and comparison with experiment

The combination of thermal and mechanical loading expected in practice means that constitutive equations of metal matrix composites must be developed which deal with time-independent and time-dependent irreversible deformation. Also, the internal state of composites is extremely complicated which underlines the need to formulate macroscopic constitutive equations with a limited number of state variables which represent the internal state at the micro level. One available method for calculating the macro properties of composites in terms of the distribution and properties of the constituent materials is the method of homogenization whose formulation is based on the periodicity of the substructure of the composite. A homogenization procedure was developed which lends itself to the use of the finite element procedure. The efficiency of these procedures, to determine the macroscopic properties of a composite system from its constituent properties, was demonstrated utilizing an aluminum plate perforated by directionally oriented slits. The selection of this problem is based on the fact that, extensive experimental results exist, the macroscopic response is highly anisotropic, and that the slits provide very high stress gradients which severely test the effectiveness of the computational procedures. Furthermore, both elastic and plastic properties were investigated so that the application to practical systems with inelastic deformation should be able to proceed without difficulty. The effectiveness of the procedures was rigorously checked against experimental results and with the predictions of approximate calculations. Using the computational results it is illustrated how macroscopic constitutive equations can be expressed in forms of the elastic and limit load behavior.

Jansson, S.↗

DOE OSTI2021

Skip-Connected Self-Recurrent Spiking Neural Networks with Joint Intrinsic Parameter and Synaptic Weight Training

As an important class of spiking neural networks (SNNs), recurrent spiking neural networks (RSNNs) possess great computational power and have been widely used for processing sequential data like audio and text. However, most RSNNs suffer from two problems. 1. Due to the lack of architectural guidance, random recurrent connectivity is often adopted, which does not guarantee good performance. 2. Training of RSNNs is in general challenging, bottlenecking achievable model accuracy. To address these problems, we propose a new type of RSNNs called Skip-Connected Self-Recurrent SNNs (ScSr-SNNs). Recurrence in ScSr-SNNs is introduced in a stereotyped manner by adding self-recurrent connections to spiking neurons. The SNNs with self-recurrent connections can realize recurrent behaviors similar to those of more complex RSNNs while the error gradients can be more straightforwardly calculated due to the mostly feedforward nature of the network. The network dynamics is enriched by skip connections between nonadjacent layers. Moreover, we propose a new backpropagation (BP) method called backpropagated intrinsic plasticity (BIP) to further boost the performance of ScSr-SNNs by training intrinsic model parameters. Unlike standard intrinsic plasticity rules that adjust the neuron's intrinsic parameters according to neuronal activity, the proposed BIP method optimizes intrinsic parameters based on the backpropagated error gradient of a well-defined global loss function in addition to synaptic weight training. Here, based on challenging speech, neuromorphic speech, and neuromorphic image datasets, the proposed ScSr-SNNs can boost performance by up to 2.85% compared with other types of RSNNs trained by state-of-the-art BP methods.

97 MATHEMATICS AND COMPUTING↗