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DOE OSTI2022

Dual-scale folding in cutting of commercially pure aluminum alloys

We examine a, hitherto, little-studied and curious machining chip morphology, with tell-tale signs of folding at two different length scales, that is common in cutting of certain ductile and highly strain-hardening metals like soft aluminum alloys, tantalum and niobium. This chip morphology does not appear in the usual catalogues of common chip types. The mechanics of formation of the “dual-scale folded chip” is studied in model material systems of commercially pure aluminum alloys (AA 1100 and AA 8040), that prominently exhibit this chip morphology. The flow, folding and associated plastic instabilities are investigated using micro/macro structure observations of the chip in a plane-strain cutting framework, with high-speed in situ imaging and image analysis of material flow; and force measurements. The smaller-scale folding is shown to develop in the primary deformation zone while the larger-scale folding occurs as the chip traverses the rake face of the tool. The resulting chip is composed of irregularly-spaced large folds, superimposed onto which are the quasi periodic small folds. The representative wavelengths of the two folds differ on average by an order of magnitude, 0.1 mm vs. 2 mm. The observations reveal a direct coupling between the material flow and chip morphology, and how specific attributes of the dual-scale folded chip arise from the flow mechanism. Plastic buckling is found to play a key role in the folding at both length scales. The small-scale folds are characteristic of a sinuous plastic flow mode, while the large-scale folding is characterized by buckling and stick-slip along the tool rake face, triggered by adhesive pinning of the chip to the tool. Important consequences of the dualscale folding are very large cutting forces, and force oscillations of large amplitude, despite the alloys being very soft, only ~ 25 HV. Here, the dual-scale folding is why many of these alloys are classified as “gummy” to machine. Since the dual-scale folded chip is associated with large cutting forces and poor surface quality, there is much to be gained by disrupting this flow type in practical machining applications. Methods for controlling the folding to improve machining performance with the gummy alloys are briefly discussed.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Thin-layer and full Navier-Stokes, locally-conical and three-dimensional asymmetric solutions

The unsteady, compressible thin-layer and full Navier-Stokes equations are used to numerically simulate steady and unsteady asymmetric, supersonic, locally-conical flows around a 5-deg-semiapex angle circular cone. The main computational scheme used for the present computations is the implicit, upwind, flux-difference splitting, finite-volume scheme. Comparisons of the solutions using the two sets of equations are presented for the flow asymmetry and its control. Computational studies are also presented to investigate the effects of the freestream Reynolds number and the locally-scaled Reynolds number on the flow asymmetry. These studies are carried out using the full Navier-Stokes equations. Three-dimensional, asymmetric flow solutions are also presented for a 5-deg-semiapex angle cone of unit length and a cone-cylinder configuration. The three-dimensional solutions are obtained by using the thin-layer equations and short-duration transient side-slip disturbances along with a very fine grid.

Kandil, O. A.↗

DOE OSTI2026

Prairie State Generating Company 2D Seismic Interpretation

The objectives of the Illinois Storage Corridor (ISC) project are to accelerate commercial deployment of carbon capture utilization and storage at two individual sites and receive approvals for Underground Injection Control (UIC) Class VI permits for construction at each site (ISC Project Narrative, 2020). As part of this project, and as part of the subsurface geologic characterization, two-dimensional (2D) seismic data was acquired at both sites. This report summarizes the findings from two phases of 2D acquisition and seismic interpretation at the Prairie State Generating Company site near Marissa, Illinois. The seismic data indicates the presence of three faults that completely transect the storage and confining units. The initial 2021 2D seismic acquisition revealed the presence of a feature two miles east of the Lively Grove #1 characterization well. The feature is a polyphase fault with a component of strike-slip motion, forming a small positive flower structure. The second phase of 2D seismic acquisition in 2022 constrained the maximum extent of the fault, indicating it has a relatively limited length. Other 2022 seismic lines revealed the presence of two other faults that transect the storage and confining units in the southwest and northeast portions of the 2D seismic acquisition area. The 2021 and 2022 2D seismic surveys have identified three specific locations within the project area that may have an elevated risk of out of zone CO 2 migration due to faulting. Further technical work will be needed to quantify this risk and determine how and if this risk will impact the placement of CO 2 injection wells across the project area.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1988

Analysis and Optimization of Truncated Scarf Nozzles Subject to External Flow Conditions

Results of a calculation of an optimized truncated scarfed nozzle were compared. The truncated scarfed nozzle was designed for an exit Mach number of 6.0, i.e., the Mach number at the last nozzle characteristic is 6.0, with an external flow Mach number of 5.0. The nozzle was designed by the Rao method for optimum thrust nozzles modified for 2-D flow and truncated scarfed nozzle applications. This design was analyzed using a shock-fitting method for 2-D supersonic flows. Excellent agreement was achieved between the design and analysis. Truncation of the lower nozzle wall (cowl) revealed that there is an optimum length for truncating the cowl without degrading the nozzle performance. Truncation of the nozzle cowl past this optimal length should be analyzed in trade-off studies for thrust loss versus gross vehicle weight. Plots of the oblique shock wave equations were also identified which will allow computation of slip line angle, dynamic pressure coefficient, or ambient Mach number for various specific heat ratios.

Shyne, Rickey J.↗

NASA NTRS1995

Nonequilibrium transport in superconducting filaments

The step-like current-voltage characteristics of highly homogeneous single-crystalline tin and indium thin filaments has been measured. The length of the samples L approximately 1 cm was much greater than the nonequilibrium quasiparticle relaxation length Lambda. It was found that the activation of a successive i-th voltage step occurs at current significantly greater than the one derived with the assumption that the phase slip centers are weakly interacting on a scale L much greater than Lambda. The observation of 'subharmonic' fine structure on the voltage-current characteristics of tin filaments confirms the hypothesis of the long-range phase slip centers interaction.

Arutyunov, K. YU.↗

DOE OSTI2025

Slippery liquid infused porous surface (SLIPS) condensers for high efficiency air gap membrane distillation

Abstract To address growing water scarcity, we must improve the energy efficiency of thermal desalination technologies such as air gap membrane distillation. However, promising functional materials such as slippery liquid infused porous surfaces have not yet implemented for any desalination technology. Here, we fabricate and test slippery liquid infused porous surfaces (using Krytox 16,256 lubricant and CuO nanostructures) in an air gap membrane distillation apparatus. System-level transport models, validated by experimental data, establish a framework for improving performance through enhanced condensation surfaces. Results are obtained across a range of temperatures (50–80 °C), salinities (5–105 g/kg), and module lengths. We find that small air gap thickness and efficient droplet shedding significantly improves performance. The CuO Krytox process achieves these with a conductive-self-limiting coating, high nanostructure rugosity, strong covalent and metallic bonding, high hydrophobicity, minimal droplet pinning sites, and ultra-low contact angle hysteresis. The greatest efficiency enhancement from SLIPS is derived from the improved droplet shedding, which allows for reduced gap sizes without flooding, and is further augmented by the increased permeate flux.

Yogi, Yashwant S.↗

NASA NTRS1989

Evidence for Phanerozoic reactivation of the Najd Fault System in AVHRR, TM, and SPOT images of central Arabia

SPOT stereoscopic and TM multispectral images support evidence in AVHRR thermal-IR images of a major unmapped shear zone in Phanerozoic cover rocks southeast of the ancient Najd Fault System in the Arabian Shield. This shear zone and faults of the Najd share a common alignment, orientation, and sinistral sense of movement. These similarities suggest a 200-km extension of the Najd Fault System and reactivation since it formed in the late Precambrian. Topographic and lithologic features in the TM and SPOT data along one of three faults inferred from the AVHRR data indicate sinistral offsets up to 2.5 km, en echelon folds and secondary faults like those predicted by models of left-lateral strike-slip faulting. The age of the affected outcrops indicates reactivation of Najd faults in the Cretaceous, judging from TM and SPOT data or in the Tertiary, based on AVHRR data. The total length of the system visible at the surface measures 1300 km. If the Najd Fault System is extrapolated beneath sands of the Empty Quarter to faults of a similar trend in South Yemen, the shear zone would span the Arabian Plate. Furthermore, if extensions into the Arabian Sea bed and into Egypt proposed by others are considered, it would exceed 3000 km.

Andre, Constance G.↗

DOE OSTI2021

Projected Seismic Activity at the Tiger Stripe Fractures on Enceladus, Saturn, From an Analog Study of Tidally Modulated Icequakes Within the Ross Ice Shelf, Antarctica

Abstract Dissipation of tidal energy is expected to generate seismicity on icy‐ocean worlds; however, the distribution and timing of this seismic activity throughout an orbital cycle is not known. We used new observations from an icy‐ocean‐world analog environment on Earth to examine the relationship between tidally driven tensile stress and seismic activity within an ice shell. We investigated a pair of rifts within Antarctica's Ross Ice Shelf which are tidally stressed in a manner analogous to the orbital cycle of tidal stress experienced by Enceladus' Tiger Stripe Fractures. We found that seismic activity at the Antarctic rifts is sensitive to both the amplitude and the rate of tensile stress across the rifts. We combined these findings with calculated stress values along Enceladus' Tiger Stripe Fractures to predict seismic‐activity levels expected along the ice‐shell fractures. We predict a peak in seismicity along the four Tiger Stripe Fractures when Enceladus is 90°–120° past pericenter in its orbit around Saturn, at which point tensile stresses would reach ∼2/3 of their maximum value. We also used the magnitude distribution of icequakes along Antarctic rifts to investigate implications for the likely size of stick‐slip rupture patches along icy faults on Enceladus. Our findings predict that the Tiger Stripe Fractures should produce sustained, low‐magnitude seismic events that involve rupture along discrete portions of each fracture's total length. We predict that seismicity would fall to 50% of peak levels when stresses across the Tiger Stripe Fractures are dominantly compressional.

Olsen, Kira G.↗

DOE OSTI2021

Nonlinear Interface Reduction for Time-Domain Analysis of Hurty/Craig-Bampton Superelements with Frictional Contact

Virtual prototyping in engineering design relies today on modern numerical models of contacting structures with accurate resolution of interface mechanics, which strongly affect the system-level stiffness and energy dissipation due to frictional losses. High-fidelity modeling within the localized interfaces is required to resolve local quantities of interest that may drive design decisions. The high-resolution finite element meshes necessary to resolve inter-component stresses tend to be computationally expensive, particularly when the analyst is interested in response time histories. The Hurty/Craig-Bampton (HCB) transformation is a widely used method in structural dynamics for reducing the interior portion of a finite element model while having the ability to retain all nonlinear contact degrees of freedom (DOF) in physical coordinates. These models may still require many DOF to adequately resolve the kinematics of the interface, leading to inadequate reduction and computational savings. This study proposes a novel interface reduction method to overcome these challenges by means of system-level characteristic constraint (SCC) modes and properly orthogonal interface modal derivatives (POIMDs) for transient dynamic analyses. Both SCC modes and POIMDs are computed using the reduced HCB mass and stiffness matrices, which can be directly computed from many commercial finite element analysis software. Comparison of time history responses to an impulse-type load in a mechanical beam assembly indicate that the interface-reduced model correlates well with the HCB truth model. Localized features like slip and contact area are well-represented in the time domain when the beam assembly is loaded with a broadband excitation. The proposed method also yields reduced-order models with greater critical timestep lengths for explicit integration schemes.

42 ENGINEERING↗

NASA NTRS1987

Regional linear cross-strike discontinuities in Western Aphrodite Terra, Venus

Western Aphrodite Terra, Venus, is characterized by a series of parallel linear structural discontinuities 2000-4000 km in length and 100-200 km wide, which strike at high angles to the general topographic trend of the highlands. The detailed characteristics of these features are similar to terrestrial oceanic fracture zones and strike-slip fault zones. Either interpretation implies the presence of large-scale horizontal tectonic movement on Venus.

Crumpler, L. S.↗

DOE OSTI2023

En echelon faults reactivated by wastewater disposal near Musreau Lake, Alberta

We use machine-learning and cross-correlation techniques to enhance earthquake detectability by two magnitude units for the earthquake sequence near Musreau Lake, Alberta, which is induced by wastewater disposal. This deep catalogue reveals a series of en echelon ~N–S oriented strike-slip faults that are favourably oriented for reactivation. These faults require only ~0.6 MPa overpressure for triggering to occur. Earthquake activity occurs in bursts, or episodes; episodes restricted to the largest fault tend to have earthquakes starting near the southern end (distant from injectors) and progressing northwards (towards the injectors). While most events are concentrated along these ~N–S oriented faults, we also delineate smaller faults. Together, these findings suggest pore pressure as the triggering mechanism, where a time-dependent increase in pore pressure likely caused these faults to progressively reawaken. Analysis of the ‘next record-breaking event’, a statistical model that forecasts the sequencing of earthquake magnitudes, suggests that the next largest event would be M L ~4.3. The seismically illuminated length of the largest fault indicates potential magnitudes as large as M w 5.3.

58 GEOSCIENCES↗

DOE OSTI2025

Strong, ductile, and hierarchical hetero-lamellar-structured alloys through microstructural inheritance and refinement

The strength−ductility trade-off exists ubiquitously, especially in brittle intermetallic-containing multiple principal element alloys (MPEAs), where the intermetallic phases often induce premature failure leading to severe ductility reduction. Hierarchical heterogeneities represent a promising microstructural solution to achieve simultaneous strength−ductility enhancement. However, it remains fundamentally challenging to tailor hierarchical heterostructures using conventional methods, which often rely on costly and time-consuming processing. Here, we report a multiscale microstructural inheritance and refinement strategy to process “structural hierarchy precursors” in as-cast heterogeneous Al 0.7 CoCrFeNi MPEAs, which lead directly to a hierarchical hetero-lamellar structure (HLS) after simple rolling and annealing. Interestingly, it takes only 10 min of annealing time, two orders of magnitude less than that required to render the state-of-the-art properties during conventional processing of Al 0.7 CoCrFeNi, for us to achieve record-high strength−ductility combinations via the hierarchical HLS design that sequentially stimulates multiple unusual deformation and reinforcement mechanisms. In particular, the HLS-enabled high hetero-deformation-induced (HDI) internal stress triggers profuse <111>-type dislocations on over five independent slip systems in the supposedly brittle intermetallic phase and activates extensive stacking faults (SFs) and nanotwinning in the adjoining soft phase with a rather high SF energy. These unexpected, dynamically reinforcing hetero-deformation mechanisms across multiple length scales facilitate high sustained HDI strain hardening, along with a salient microcrack-mediated extrinsic ductilization effect, suggesting that the proposed microstructural inheritance and refinement strategy provides an efficient, fast, and low-cost approach to overcome the strength−ductility trade-off in a broad range of structural materials.

Science & Technology - Other Topics↗

DOE OSTI2020

Advanced Geomechanical Model to Predict the Impact of CO2-Induced Microstructural Alterations on the Cohesive-Frictional Behavior of Mt. Simon Sandstone

We investigated the influence of CO2-induced geochemical reactions on the cohesive-frictional properties of host rock within the context of CO2 storage in a saline aquifer and focused on the Mt. Simon sandstone. The research objective was to model geo-mechanical changes due to host rock exposure to CO2-saturated brine while accounting for heterogeneity, double-scale porosity, and granular structure. We formulated a three-level multi-scale model for host rocks. We conducted scanning electron microscopy analyses to probe the microstructure and grid nanoindentation to measure the mechanical response. We derived new nonlinear strength upscaling solutions to correlate the effective strength characteristics and the macroscopic yield surface to the micro-structure at the nano-, micro-, and meso-scales. Specifically, our theoretical model links CO2-induced microstructural alterations to a reduction in the size of the yield surface, and a drop in the value of the friction coefficient. In turn, regarding the Illinois Basin Decatur Project, the CO2-induced drop in friction coefficient is linked to an increase in the risk of fault slip and a higher probability of induced microseismicity during and after the end of CO2 underground injection operations. The theoretical model presented is essential for the geo-mechanical modeling of CO2 underground injection operations at multiple length-scales.

58 GEOSCIENCES↗

NASA NTRS2010

International Space Station Major Constituent Analyzer On-Orbit Performance

The Major Constituent Analyzer is a mass spectrometer based system that measures the major atmospheric constituents on the International Space Station. A number of limited-life components require periodic changeout, including the analyzer (ORU 02) and the verification gas assembly (ORU 08). The longest lasting ORU 02 was recently replaced after a record service length of 1033 days. The comparatively high performance duration may be attributable to a reduced inlet flow rate into the analyzer, resulting in increased ion pump lifetime; however, there may be other factors as well. A recent schedule slip for delivery of replacement verification gas led to a demonstration that the calibration interval could be extended on a short-term basis. An analysis of ORU 08 performance characteristics indicates that it is possible to temporarily extend the calibration interval from 6 weeks to 12 weeks if necessary.

Gardner, Ben D.↗

NASA NTRS1991

Three-dimensional Navier-Stokes asymmetric solutions for cones and cone-cylinder configurations

The unsteady, compressible, thin-layer Navier-Stokes equations are used to obtain three-dimensional, asymmetric, vortex-flow solutions around cones and conecylinder configurations. The equations are solved using an implicit, upwind, flux-difference splitting, finite-volume scheme. The computational applications cover asymmetric flows around a 5 deg semiapex angle cone of unit length at various Reynolds number. Next, a cylindrical afterbody of various length is added to the conical forebody to study the effect of the length of cylindrical afterbody on the flow asymmetry. One of the computational solutions has been validated by comparing the computed surface pressure with those of the experimental data. All the asymmetric flow solutions have been obtained by using a short-duration side-slip disturbance.

Kandil, Osama A.↗

NASA NTRS1991

Skin friction and heat transfer correlations for high-speed low-density flow past a flat plate

The independent and dependent variables associated with drag and heat transfer to a flat plate at zero incidence in high-speed, rarefied flow are analyzed anew to reflect the importance of kinetic effects occurring near the plate surface on energy and momentum transfer, rather than following arguments normally used to describe continuum, higher density flowfields. A new parameter, the wall Knudsen number Knx,w, based on an estimate of the mean free path length of molecules having just interacted with the surface of the plate, is introduced and used to correlate published drag and heat transfer data. The new parameter is shown to provide better correlation than either the viscous interaction parameter X or the widely-used slip parameter Voo for drag and heat transfer data over a wide range of Mach numbers, Reynolds numbers, and plate-to-freestream stagnation temperature ratios.

Woronowicz, Michael S.↗

DOE OSTI2021

Combined Structural Analysis of Core and Image Log of TGH 76-31 South East of Mt Baker, Washington State

Despite active volcanism, few geothermal energy resources have been developed in the Cascades Range. Temperature Gradient Hole 76-31 was drilled to ~440 m measured depth to probe for zones where fractures provide fluid conduits that transport deep volcanic heat to shallow depths that could support baseload, carbon neutral electrical generation. These zones were predicted by a Play Fairway assessment (PFA) of resource potential along a zone 11 km west-southwest of the summit of Mount Baker Volcano. Rock core, temperature logs, and an acoustic image log were obtained. By comparison to outcrops, the core has been initially interpreted as the Chilliwack group comprised of partially metamorphosed basaltic to andesitic volcanics. Core mapping reveals complex, steeply dipping networks of fractures and brecciation along slickensided strike slip faults; clay alteration is common in many of these structures. The majority of fractures are thoroughly healed by layers of chlorite and calcite; preservation of pyrite indicates anoxic conditions. The majority of fracture porosity resides in very dense fractures a few centimeters or less in length. The image log provides good insights into attitude of fractures that fully transect the core, but generally underestimates fracture density. The combination of complex, non-planar fracture zones containing many short fractures and healing promote misinterpretation of natural fracture attitude and density in the image log. The healing and anoxic minerals are consistent with the conductive temperature gradient measured in the well below a shallow isothermal zone, although, several fractures are open or only partially healed and resulted in fluid entries into the well. Here, the equilibrated measured temperature gradient of 64ºC/km and calculated heat flow of 145 mW/m2 is more than twice the regional average, indicating local influence of the Mt Baker magmatic system at the Little Park Creek TGH site.

Cascades↗

DOE OSTI2020

Simulating the mechanisms of serrated flow in interstitial alloys with atomic resolution over diffusive timescales

Abstract The Portevin-Le Chatelier (PLC) effect is a phenomenon by which plastic slip in metallic materials becomes unstable, resulting in jerky flow and the onset of inhomogeneous deformation. The PLC effect is thought to be fundamentally caused by the dynamic interplay between dislocations and solute atoms. However, this interplay is almost always inaccessible experimentally due to the extremely fine length and time scales over which it occurs. In this paper, simulations of jerky flow in W-O interstitial solid solutions reveal three dynamic regimes emerging from the simulated strain rate-temperature space: one resembling standard solid solution strengthening, another one mimicking solute cloud formation, and a third one where dislocation/solute coevolution leads to jerky flow as a precursor of dynamic strain aging. The simulations are carried out in a stochastic framework that naturally captures rare events in a rigorous manner, providing atomistic resolution over diffusive time scales using no adjustable parameters.

36 MATERIALS SCIENCE↗