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NASA NTRS1989

Improving the low temperature ductility of NiAl

As part of a study aimed at developing a ductile NiAl-based alloy, ingots of Ni-Fe-Al alloys were cast and hot extruded to rods. The purpose of the iron additions was two-fold viz; to produce a change in the slip vector from 001 to 111 line and, in one alloy, to add a L1(2)-structured ductile second phase. Extruded Ni-20Al-30Fe was two-phase, containing a pro-eutectic B2 phase in a fine lamellar structure of B2+L1(2) phases. Room temperature tensile testing of both single extruded and double extruded alloys resulted in 8-percent and 22-percent plastic elongation and yield stresses of 850 and 760 MPa, respectively. Fracture in both cases occurred by ductile tearing of the eutectic and transgranular cleavage of the proeutectic phase at 1350 MPa. The ductility in double extruded condition is higher than that reported earlier in rapidly solidified wires by Inoue et al. (1984). By comparison, extruded single-phase B2-structured Ni-30Al-20Fe exhibited a fracture strength of 780 MPa, no plasticity, and a mixture of intergranular fracture and transgranular cleavage. This is contrast to earlier work by Inoue et al. where a yield stress of 400 MPa, 5 percent plastic strain, and a mixture of dimple and intergranular fracture was reported.

Guha, Sumit↗

NASA NTRS1976

Plastic deformation of polycrystalline zirconium carbide

The compressive yield strength of arc-melted polycrystalline zirconium carbide has been found to vary from 77 kg per sq mm at 1200 C to 19 kg per sq mm at 1800 C. Yield drops were observed with plastic strain-rates greater than 0.003/sec but not with slower strain rates. Strain-rate change experiments yielded values for the strain-rate sensitivity parameter m which range from 6.5 at 1500 C to 3.8 at 1800 C, and the product dislocation velocity stress exponent times T was found to decrease linearly with increasing temperature. The deformation rate results are consistent with the Kelly-Rowcliffe model in which the diffusion of carbon assists the motion of dislocations.

Darolia, R.↗

DOE OSTI2024

On plasticity-enhanced interfacial toughness in bonded joints

Here, the performance and reliability of many structures and components depend on the integrity of interfaces between dissimilar materials. Interfacial toughness Γ is the key material parameter that characterizes resistance to interfacial crack growth, and Γ is known to depend on many factors including temperature. For example, previous work showed that the toughness of an epoxy/aluminum interface decreased 40 % as the test temperature was increased from -60 °C to room temperature (RT). Interfacial integrity at elevated temperatures is of considerable practical importance. Recent measurements show that instead of continuing to decrease with increasing temperature, Γ increases when test temperature is above RT. Cohesive zone finite element calculations of an adhesively bonded, asymmetric double cantilever beam specimen of the type used to measure Γ suggest that this increase in toughness may be a result of R-curve behavior generated by plasticity-enhanced toughening during stable subcritical crack growth with interfacial toughness defined as the critical steady-state limit value. In these calculations, which used an elastic-perfectly plastic epoxy model with a temperature-dependent yield strength, the plasticity-enhanced increase in Γ above its intrinsic value Γ o depended on the ratio of interfacial strength σ* to the yield strength σyb of the bond material. There is a nonlinear relationship between Γ/Γ o and σ*/σ yb with the value Γ/Γ o increasing rapidly above a threshold value of σ*/σ yb . The predicted increase in toughness can be significant. For example, there is nearly a factor of two predicted increase in Γ/Γ o during micrometer-scale crack-growth when σ*/σ yb = 2 (a reasonable choice for σ*/σ yb ). Furthermore, contrary to other reported results, plasticity-enhanced toughening can occur prior to crack advance as the cohesive zone forms and the peak stress at the tip of the original crack tip translates to the tip of the fully formed cohesive zone. These results suggest that plasticity-enhanced toughening should be considered when modeling interfaces at elevated temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Transient Chemo‐Mechanical Model of Lithium Plating Impacted by External Pressure

Abstract Lithium anodes show great promise in commercial applications, but are hindered by lithium plating and dendrite growth which cause safety concerns during long‐term cell operation. Stack pressure is experimentally observed to improve cell lifetime; however, the relationship between stress and lithium deposition has remained difficult to elucidate. In this work, a transient, 3D, finite‐element model of the evolution of a lithium anode due to stripping and plating is developed. The evolution of a microscale protrusion on the anode surface is tracked over one charge‐discharge cycle with respect to stack pressure and lithium yield strength. Lithium plastic deformation, nonconformal anode‐separator contact, and separator porosity effects are accounted for. Over the course of several hours of stripping/plating, the anode surface evolves to a similar morphology under pressure regardless of the initial conditions due to lithium plastic deformation and hardening. The rate of this evolution highly depends on the applied pressure and assumed lithium yield strength.

25 ENERGY STORAGE↗

NASA NTRS1986

Constitutive modeling for isotropic materials

The objective of the program is to evaluate and develop existing constitutive models for use in finite-element structural analysis of turbine engine hot section components. The class of constitutive equation studied is considered unified in that all inelastic deformation including plasticity, creep, and stress relaxation are treated in a single term rather than a classical separation of plasticity (time independent) and creep (time dependent) behavior. The unified theories employed also do not utilize the classical yield surface or plastic potential concept. The models are constructed from an appropriate flow law, a scalar kinetic relation between strain rate, temperature and stress, and evolutionary equations for internal variables describing strain or work hardening, both isotropic and directional (kinematic). This and other studies have shown that the unified approach is particularly suited for determining the cyclic behavior of superalloy type blade and vane materials and is entirely compatible with three-dimensional inelastic finite-element formulations. The behavior was examined of a second nickel-base alloy, MAR-M247, and compared it with the Bodner-Partom model, further examined procedures for determining the material-specific constants in the models, and exercised the MARC code for a turbine blade under simulated flight spectrum loading. Results are summarized.

Lindholm, Ulric S.↗

NASA NTRS2016

Plasticity Tool for Predicting Shear Nonlinearity of Unidirectional Laminates Under Multiaxial Loading

This study implements a plasticity tool to predict the nonlinear shear behavior of unidirectional composite laminates under multiaxial loadings, with an intent to further develop the tool for use in composite progressive damage analysis. The steps for developing the plasticity tool include establishing a general quadratic yield function, deriving the incremental elasto-plastic stress-strain relations using the yield function with associated flow rule, and integrating the elasto-plastic stress-strain relations with a modified Euler method and a substepping scheme. Micromechanics analyses are performed to obtain normal and shear stress-strain curves that are used in determining the plasticity parameters of the yield function. By analyzing a micromechanics model, a virtual testing approach is used to replace costly experimental tests for obtaining stress-strain responses of composites under various loadings. The predicted elastic moduli and Poisson's ratios are in good agreement with experimental data. The substepping scheme for integrating the elasto-plastic stress-strain relations is suitable for working with displacement-based finite element codes. An illustration problem is solved to show that the plasticity tool can predict the nonlinear shear behavior for a unidirectional laminate subjected to multiaxial loadings.

Wang, John T.↗

DOE OSTI2025

Hyperelastic nature of the Hoek–Brown criterion

In this article, we propose a nonlinear elasto-plastic model, for which a specific class of hyperbolic elasticity arises as a straight consequence of the yield criterion invariance on the plasticity level. We superimpose this nonlinear elastic (or hyperelastic) behavior with plasticity obeying the associated flow rule. Interestingly, we find that a linear yield criterion on the thermodynamical force associated with plasticity results in a quadratic yield criterion in the stress space. This suggests a specific hyperelastic connection between Mohr–Coulomb and Hoek–Brown (or alternatively between Drucker–Prager and Pan–Hudson) yield criteria. We compare the elasto-plastic responses of standard tests for the Drucker–Prager yield criterion using either linear or the suggested hyperbolic elasticity. Notably, the nonlinear case stands out due to dilatancy saturation observed during cyclic loading in the triaxial compression test. We conclude this study with structural finite element simulations that clearly demonstrate the numerical applicability of the proposed model.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Surface Modified Fly Ash for Value Added Products (SuMo Fly Ash)

The objective of this project is to develop a technology to encapsulate coal fly ash particles in sulfurized vegetable oil, enhancing physical and mechanical properties of the fly ash as a filler material when applied in commercial products. This project significantly advances the knowledge base and technology for synthesizing coated fly ash particles for application in different polymer matrices to increase cross-linking, compatibility, air-entrainment and to decrease the leaching potential of metals of concern. Specifically, the project focuses on (a) collection, and characterization of fly ash material from coal power plants; (b) development of Sulfurized Vegetable Oil (SVO) modified (SuMo) fly ash and their detailed characterization; (c) evaluation of the mechanical properties of the SuMo fly ash incorporated plastic and rubber composites for potential replacement of CaCO 3 or carbon black as filler materials with SuMo fly ash in plastic and rubber composites; (d) leaching potential of SuMo fly ash and SuMo fly ash-incorporated plastic and rubber composites to determine the rate of release of trace metals. The major findings of this project are: i) Sulfurized Vegetable Oil coated fly ash (SuMo fly ash) was successfully prepared with a particle size of ≤ 45 micron which exhibited hydrophobicity of contact angle > 90°; ii) the coating reduces leaching of metals (e.g., B, Cr) from fly ash when exposed to water; iii) incorporation of SuMo fly ash increases thermal stability and yield strength of plastics; iv) SuMo coating helps disperse fly ash particles into cured rubbers, natural rubber; (v) SuMo fly ash-incorporated plastic/cured rubbers compounds protects against leaching of toxic elements.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Multiscale plasticity of geomaterials predicted via constrained optimization‐based granular micromechanics

Abstract A general framework to derive nonlinear elastic and elastoplastic material models from granular micromechanics is proposed, where a constraint‐based variational structure is introduced to classical grain contact‐based homogenization methods of hyperelasticity. Like the classical hyperelastic methods, reference solutions for closed‐form hyperelastic material models are analytically derived from the grain‐scale contact mechanics. However, unlike prior methods, the proposed homogenization framework defines closed‐form hyperelastoplastic material models that extend multiscale variational methods to granular plasticity. The proposed framework is used to develop novel granular micromechanics‐based macroscopic models for a Mises type solid, Drucker–Prager type plasticity, and grain‐contact cohesive‐debonding with a deviatorically and volumetrically coupled nonlinearly elastic response. Macroscopic plastic parameters and yield criteria are explicitly related to their microscale counterparts, for example, the friction coefficient governing intergranular slip. Numerical examples and comparison to measurements from the literature, including triaxial compaction of concrete, are provided to investigate model predictions and demonstrate calibration to experimental data.

Bryant, E. C.↗

DOE OSTI2025

Rheological Properties of Enzymatically Hydrolyzed Corn Stover Pretreated via Deacetylation and Mechanical Refining

Lignocellulosic biomass is a feedstock for fuels and chemicals that does not compete with food resources and has less contaminants than refuse-derived biomass feedstocks. To convert lignocellulosics to biofuels or value-added products, multiple processing steps are typically necessary. One method of producing biofuels from lignocellulosic biomass utilizes a deacetylation and mechanical refining pretreatment and an enzymatic hydrolysis reaction to produce fermentable sugars from cellulose and hemicellulose. The rheological properties of biomass, such as yield stress and plastic viscosity, change during enzymatic hydrolysis and alter the energy requirements for pumping and mixing, an important consideration for the design of processing equipment. The dynamic changes in rheological properties that occur in a corn stover feedstock undergoing enzymatic hydrolysis are characterized in this work, and the influence on pressure losses in piping systems is estimated. Two rheometer geometries were fabricated with stereolithography 3D printing to reduce wall slip and sample ejection. The slurries have complex rheological behaviors that include shear-thinning behavior. Shear stress ramps were performed on samples at 20 and 50 degrees C using the custom geometries, and the Herschel-Bulkley model was fit to the data. The dynamic nature of the rheological properties is correlated with changes in the average fiber length at various extents of reaction, and the influence of solids concentration on the observed rheology and piping pressure losses is discussed.

09 BIOMASS FUELS↗

NASA NTRS1972

The line spring model for surface flaws.

A model is discussed for the analysis of long part-through surface cracks in the walls of plate or shell structures. Such problems are formulated within the context of two dimensional plate and shell theory with the part-cracked section represented as a line-spring in the middle surface. The spring allows relative separations and rotations of the middle surface, and constitutive laws relating these discontinuities to the prevailing force and moment per unit length at any point are taken from the plane strain solution for a strip in combined tension and bending, which contains an edge crack of a corresponding depth. Prior work is reviewed and further line spring constitutive laws are discussed as appropriate to elastic analysis with thermal or residual stresses and to elastic-plastic analysis, with yielding in the ligament between the crack front and far wall in the latter case.

Rice, J. R.↗

NASA NTRS1974

Fracture mechanics analysis of a high-pressure hydrogen facility compressor

The investigation and analysis of a high-pressure hydrogen facility compressor is chronicled, and a life prediction based on fracture mechanics is presented. Crack growth rates in SA 105 Gr II steel are developed for the condition of sustained loading, using a hypothesis of hydrogen embrittlement associated with plastic zone reverse yielding. The resultant formula is compared with test data obtained from laboratory specimens.

Vroman, G. A.↗

NASA NTRS1985

Fillet Weld Stress Using Finite Element Methods

Average elastic Von Mises equivalent stresses were calculated along the throat of a single lap fillet weld. The average elastic stresses were compared to initial yield and to plastic instability conditions to modify conventional design formulas is presented. The factor is a linear function of the thicknesses of the parent plates attached by the fillet weld.

Lehnhoff, T. F.↗

NASA NTRS1987

Thermo-elasto-viscoplastic analysis of problems in extension and shear

The problems of extension and shear behavior of structural elements made of carbon steel and subjected to large thermomechanical loads are investigated. The analysis is based on nonlinear geometric and constitutive relations, and is expressed in a rate form. The material constitutive equations are capable of reproducing all nonisothermal, elasto-viscoplastic characteristics. The results of the test problems show that: (1) the formulation can accommodate very large strains and rotations; (2) the model incorporates the simplification associated with rate-insensitive elastic response without losing the ability to model a rate-temperature dependent yield strength and plasticity; and (3) the formulation does not display oscillatory behavior in the stresses for the simple shear problem.

Riff, R.↗

NASA NTRS1988

Thermo-elasto-viscoplastic analysis of problems in extension and shear

Riff, R.↗

NASA NTRS1955

Effect of Surface-active Additives on Physical Properties of Slurries of Vapor-process Magnesium

The presence of 3 to 5 percent surface-active additive gave the lowest Brookfield apparent viscosity, plastic viscosity, and yield value that were obtained for slurry fuels containing approximately 50 percent vapor-process magnesium in JP-1 fuel. The slurries settled little and were easily remixed. A polyoxyethylene dodecyl alcohol was the most effective of 13 additives tested in reducing the Brookfield apparent viscosity and the yield value of the slurry. The seven most effective additives all had a hydroxyl group plus an ester or polyoxethylene group in the molecule. The densities of some of the slurries were measured.

Pinns, Murray L↗

DOE OSTI2022

Decontamination of Mixed Paper and Plastic Municipal Solid Waste Increases Low and High Temperature Conversion Yields

With the implementation of China’s Green Fence Policy and the following National Sword Policy, there is a need to divert previously accepted waste materials away from the landfill. Mixed plastic and paper wastes that are too contaminated to be economically recycled can be used for conversion into fuels and products. The effect of common contaminants present in waste streams must be determined to make municipal solid waste (MSW) a viable alternative to agricultural feedstocks for conversion. In this study, MSW was sourced from a dual stream materials recovery facility (MRF) in Emmet County, Michigan and characterized via mass balance. The most common contaminants in mixed paper and plastic were quantified and targeted for decontamination when mixed paper was explored for low temperature conversion pathways and plastics for high temperature conversion pathways. Ink, stickies, and plastic contamination were sorted out of the mixed paper stream and did not have an impact on sugar yields during enzymatic hydrolysis (EH). Although no improvement in yield was found, it was noted that copy paper within the mixed paper stream had an elevated pH and higher concentration of fermentation inhibitors, suggesting that intrinsic properties of some paper types may not be ideal for EH and fermentation conversion. Dilute alkaline pretreatment and mechanical refining of mixed paper increased the EH yield of mixed paper, suggesting this previously established process could be used as a decontamination method. “Dirt” and particulates were washed from mixed plastic using either an aqueous detergent or a non-aqueous chemical washing method. Liquid oil yields were increased during microwave assisted fast pyrolysis. All decontamination techniques met the cost target of less than $30/dry ton with plastic decontamination ranging from $18.16 to $24.81/dry ton. Because dilute alkaline pre-treatment and mechanical refining is considered part of the conversion process, the decontamination cost during feedstock preprocessing was considered $0/dry ton.

09 BIOMASS FUELS↗

DOE OSTI2021

Rheology of fresh cement pastes containing polymer nanoparticles

Influences of polymer nanoparticles (PNPs) with varied charge densities on the rheological behaviors of fresh cement pastes (fcps) without and with polycarboxylate superplasticizer (PCE) were studied. In the blank fcp, the addition of PCE and highly anionically charged PNPs greatly decreases the yield stress and the plastic viscosity due to their large adsorption on cement that produces electrostatic repulsion and steric hindrance between cement grains. However, the non-adsorbing nonionic PNPs show a slightly opposite effect. In the PCE-containing fcp, both the anionic and nonionic PNPs become non-adsorbing on cement due to the stronger affinity of PCE to cement surface. In this way, the addition of the PNPs in the PCE-containing fcp slightly increases the yield stress and the plastic viscosity, but significantly decreases the pseudoplastic index, which is believed to result from the generation of the so-called depletion attractive force between cement grains induced by the non-adsorbing polymers.

36 MATERIALS SCIENCE↗