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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Preparation, mechanical properties, and toughening mechanisms of SiCw/SiCp‐reinforced zirconia‐toughened alumina ceramics

ABSTRACT Zirconia‐toughened alumina (ZTA) ceramics with high mechanical properties were sintered by hot‐pressing method using SiC particles (SiCp) and SiC whiskers (SiCw) as the reinforcing agents simultaneously. The influences of sintering temperature, SiCp, and SiCw contents on the microstructure and mechanical properties of ZTA ceramics were investigated. It was found that both SiCp and SiCw could contribute to grain refinement significantly and promote the mechanical properties of the ceramics. However, the excess addition of SiCp or SiCw led to the formation of pores with large sizes and degraded the mechanical properties instead. When 13 wt% SiCp was introduced, the maximum flexural strength of 1180.0 MPa and fracture toughness of 15.9 MPa·m 1/2 were obtained, whereas the maximum flexural strength of 1314.0 MPa and fracture toughness of 14.7 MPa·m 1/2 were achieved at 20 wt% SiCw. Interestingly, the simultaneous addition of SiCp and SiCw could further improve the mechanical properties, and the highest flexural strength of 1334.0 MPa and fracture toughness of 16.0 MPa·m 1/2 were achieved at a SiCw/SiCp ratio of 16/4. The reinforcement mechanisms in the ceramics mainly included the phase transformation toughening of ZrO 2 , the crack deflection and bridging of SiCp and SiCw, and the pull‐out of SiCw.

Liu, Longyang↗

DOE OSTI2012

Pathway Controlled Penetration (PcP) [Slides]

The technical approach employs advanced computational simulation tools to demonstrate how current assets can destroy RWK-RFI-12-0001's HDBT, a tunnel complex with two portals built into the base of a granite mountain. The granite over layer is assumed to be 60 meters thick over both portals and 80 meters over the facility's mission space. Key S&T is the completed development of a highly innovative viscoplastic fracture material model, 3D parallel gas-fracture capabilities into FDEM, and a stochastic handling of the material properties. Phase I - Develop and validate code simulation tools: (1) develop, incorporate and validate AZ-Frac material model for granite; and (2) Develop and incorporate gas-driven-fracture modeling into LANL's FDEM MUNROU code; (3) Develop and incorporate stochastic features into FDEM modeling. Phase II - Conduct PcP analysis on above HDBT: (1) Acquire HDBT design data, develop simulation model; and (2) Evaluate and select most promising defeat alternative. Phase III - Deliver code, train Service target analysts, and conduct simulations against real world HDBTs. PcP uses advanced computer simulations to enhance HDBT functional defeat efforts. Newly developed material models that account for fractural energy coupled with the finite discrete element methodology (FDEM) will provide targeting packages that will create penetration avenues for current or future lethality options. This novel computational approach requires full 3D geologic and structure characterization as well as significant high performance computing capabilities. The goal is to distinctively alter the targeting paradigm by leveraging critical DoD assets along with insitu geologic strata. In other words, assets will utilize underground rock structure to their benefit by creating rubbilization zones that will allow pathway controlled penetration.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2018

Effects of Controlled Cooling-Induced Ferrite–Pearlite Microstructure on the Cold Forgeability of XC45 Steel

The combination of hot/warm and cold forging with an intermediate controlled cooling process is a promising approach to saving costs in the manufacture of automobile parts. In this work, the effects of the ferrite–pearlite microstructure, which formed after controlled cooling, on the cold forgeability of a medium-carbon steel were investigated. Different specimens for both normal and notched tensile tests were directly heated to high temperature and then cooled down at different cooling rates, producing different ferrite volume fractions, ranging from 6.69 to 40.53%, in the ferrite–pearlite microstructure. The yield strength, ultimate tensile strength, elongation rate, percentage reduction of area, and fracture strain were measured by tensile testing. The yield strength, indicating deformation resistance, and fracture strain, indicating formability, were used to evaluate the cold forgeability. As the ferrite volume fraction increased, the cold forgeability of the dual-phase ferritic–pearlitic steel improved. A quantitatively relationship between the ferrite volume fraction and the evaluation indexes of cold forgeability for XC45 steel was obtained from the test data. To validate the mathematical relationship, different tensile specimens machined from real hot-forged workpieces were tested. There was good agreement between the predicted and measured values. Our predictions from the relationship for cold forgeability had an absolute error less than 5%, which is acceptable for industrial applications and will help to guide the design of combined forging processes.

36 MATERIALS SCIENCE↗

DOE OSTI2020

A machine learning approach to fracture mechanics problems

Analytical and empirical solutions to engineering problems are usually preferred because of their convenience in applications. However, they are not always accessible in complex problems. A new class of solutions, based on machine learning (ML) models such as regression trees and neural networks (NNs), are proposed and their feasibility and value are demonstrated through the analysis of fracture toughness measurements. It is found that both solutions based on regression trees and NNs can provide accurate results for the specific problem, but NN-based solutions outperform regression-tree-based solutions in terms of their simplicity. Here this example demonstrates that ML solutions are a major improvement over analytical and empirical solutions in terms of both reliable functionality and rapid deployment. When analytical solutions are not available, the use of ML solutions can overcome the limitations of empirical solutions and substantially change the way that engineering problems are solved.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Unveiling stimulation fluid-driven alterations in shale pore architecture through combined interpretation of TD-NMR and multi-component gas adsorption

The hydraulic fracturing stimulation process can alter petrophysical and flow properties of the shale matrix in unconventional reservoirs. These alterations can result from interactions with native and exogenous fluids, and can be detrimental to reservoir productivity. Different experimental procedures have been proposed to study reactive processes and thereby understand the aforementioned interactions. Most published works do not consider the rock initial saturation with formation fluid, or the effect of organic matter (OM). To gain insights into these effects, two reactive experimental sets, differing in experimental conditions, were conducted. In the first set, at 125°C and 45 MPa, a stimulation fluid surrogate was put in contact with Baxter Shale samples, previously saturated and equilibrated with synthetic formation fluid. A baseline consisted of exposure to formation fluid exclusively. In the second set, at 0.08 MPa and 25°C, contact with stimulation fluid took place as in the first set. Two additional assays in this second set either skipped the initial formation fluid saturation or removed the OM, respectively. Petrophysical properties analyses, focused on the pore architecture, relied on the combined interpretation of gas adsorption and Time-Domain Nuclear Magnetic Resonance (TD-NMR). Results show that the presence of the formation fluid significantly restricts pore space accessibility to the stimulation fluid and mitigates the pore-architecture alteration to the macro-pore region. Mineral dissolution and precipitation dominate over surface or wettability alteration. Next, results suggest that the OM restricts accessibility to some pores. Ultimately, the equilibration process with synthetic formation fluid drives mainly surface alteration, unhindered by OM.

58 GEOSCIENCES↗

DOE OSTI2015

Numerical simulations of vertical growth of hydraulic fractures and brine migration in geological formations above the Marcellus shale

One of the critical environmental questions about hydraulic fracturing in shales is the potential for contamination of ground and surface water. There are two specific concerns arising from hydraulic treatments: 1) whether hydraulic fractures extend upward through overlying strata to reach overlying aquifers containing drinking water, and 2) whether injected fluids push native fluids upward into these overlying aquifers. In this work, the extent of likely fracture growth through overlying layers during hydraulic treatment of the Marcellus shale was estimated using a hydraulic fracture model. A wide range of material and fluid flow properties in a multi-layered geologic model was considered. The model was based on conditions and characteristics applicable to the Marcellus shale in that part of the Appalachian basin within southwestern Pennsylvania. Predictions of vertical termination frequencies for hydraulic fractures were used in a multi-layer model of the strata and natural fractures for studying brine migration through the natural and induced fracture network. NFFLOW, the software for explicitly modeling flow within networks of fractures, was utilized to compute transient flow rates according to the schedule of injected fluid during hydraulic fracturing. To aid our analysis, the modeled sequence of geologic strata was capped with a fictitious unfractured, but moderately-permeable layer, which serves as a monitoring zone. The analysis assumes one well lateral was placed in the middle of the Marcellus shale with hydraulic fractures penetrating layers in the model. The newly-developed geomechanical module within NFFLOW was used to represent stress-sensitivity of the fractures. This allows the opening and closing of fracture apertures with changes in fluid pressures within fracture segments. Pressure increases in the formations overlying the Tully limestone, indicating fluid flow, was observed due to the hydraulic stimulation; and the impact of these increased pressures on brine migration towards the surface was considered.

03 NATURAL GAS↗

DOE OSTI2011

IS SGR 0418+5729 INDEED A WANING MAGNETAR?

SGR 0418+5729 is a transient soft gamma-ray repeater which underwent a major outburst in 2009 June, during which the emission of short bursts was observed. Its properties appeared quite typical of other sources of the same class until long-term X-ray monitoring failed to detect any period derivative. The present upper limit on P-dot implies that the surface dipole field is B{sub p} {approx}< 7.5 x 10{sup 12} G, well below those measured in other soft gamma-ray repeaters (SGRs) and in the Anomalous X-ray Pulsars (AXPs), a group of similar sources. Both SGRs and AXPs are currently believed to be powered by ultra-magnetized neutron stars (magnetars, B{sub p} {approx} 10{sup 14}-10{sup 15} G). SGR 0418+5729 hardly seems to fit in such a picture. We show that the magneto-rotational properties of SGR 0418+5729 can be reproduced if this is an aged magnetar, {approx}1 Myr old, which experienced substantial field decay. The large initial toroidal component of the internal field required to match the observed properties of SGR 0418+5729 ensures that crustal fractures, and hence bursting activity, can still occur at the present time. The thermal spectrum observed during the outburst decay is compatible with the predictions of a resonant Compton scattering model (as in other SGRs/AXPs) if the field is low and the magnetospheric twist is moderate.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2012

Modelling the graphite fracture mechanisms

In order to define a design criterion for graphite components, it is important to identify the physical phenomena responsible for the graphite fracture, to include them in a more effective modelling. In a first step, a large panel of experiments have been realised in order to build up an important database; results of tensile tests, 3 and 4 point bending tests on smooth and notched specimens have been analysed and have demonstrated an important geometry related effects on the behavior up to fracture. Then, first simulations with an elastic or an elastoplastic bilinear constitutive law have not made it possible to simulate the experimental fracture stress variations with the specimen geometry, the fracture mechanisms of the graphite being at the microstructural scale. That is the reason why a specific F.E. model of the graphite structure has been developed in which every graphite grain has been meshed independently, the crack initiation along the basal plane of the particles as well as the crack propagation and coalescence have been modelled too. This specific model has been used to test two different approaches for fracture initiation: a critical stress criterion and two criteria of fracture mechanic type. They are all based on crystallographic considerations as a global critical stress criterion gave unsatisfactory results. The criteria of fracture mechanic type being extremely unstable and unable to represent the graphite global behaviour up to the final collapse, the critical stress criterion has been preferred to predict the results of the large range of available experiments, on both smooth and notched specimens. In so doing, the experimental observations have been correctly simulated: the geometry related effects on the experimental fracture stress dispersion, the specimen volume effects on the macroscopic fracture stress and the crack propagation at a constant stress intensity factor. In addition, the parameters of the criterion have been related to experimental observations: the local crack initiation stress of 8 MPa corresponds to the non-linearity apparition on the global behavior observed experimentally and the the maximal critical stress defined for the particle of 30 MPa is equivalent to the fracture stress of notched specimens. This innovative combination of crack modelling and a local crystallographic critical stress criterion made it possible to understand that cleavage initiation and propagation in the graphite microstructure was driven by a mean critical stress criterion. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2012

The Bakken-An Unconventional Petroleum and Reservoir System

An integrated geologic and geophysical study of the Bakken Petroleum System, in the Williston basin of North Dakota and Montana indicates that: (1) dolomite is needed for good reservoir performance in the Middle Bakken; (2) regional and local fractures play a significant role in enhancing permeability and well production, and it is important to recognize both because local fractures will dominate in on-structure locations; and (3) the organic-rich Bakken shale serves as both a source and reservoir rock. Results from the lithofacies, mineral, and fracture analyses of this study were used to construct a dual porosity Petrel geo-model for a portion of the Elm Coulee Field. In this field, dolomitization enhances reservoir porosity and permeability. First year cumulative production helps locate areas of high well productivity and in deriving fracture swarm distribution. A fracture model was developed based on high productivity well distribution, and regional fracture distribution, and was combined with favorable matrix properties to build a dual porosity geo-model.

02 PETROLEUM↗

NASA NTRS1974

Factors affecting the thermal shock resistance of several hafnia based composites containing graphite or tungsten

The thermal shock resistance of hafnia based composites containing graphite powder or tungsten fibers was investigated in terms of material properties which include thermal expansion, thermal conductivity, compressive fracture stress, modulus of elasticity, and phase stability in terms of the processing parameters of hot pressing pressure and/or density, degree of stabilization of the hafnia, and composition. All other parameters were held constant or assumed constant. The thermal shock resistance was directly proportional to the compressive fracture stress to modulus of elasticity ratio and was not affected appreciably by the small thermal expansion or thermal conductivity changes. This ratio was found to vary strongly with the composition and density such that the composites containing graphite had relatively poor thermal shock resistance, while the composites containing tungsten had superior thermal shock resistance.

Lineback, L. D.↗

NASA NTRS1976

Creation of a ceramics handbook

A group of common ceramic materials (alumina, magnesium oxide, silicon nitride, and silicon carbide) were characterized through literature searches according to their physical properties. The files used were the NASA file, DDC/GRA File, Engineering Index File and standard library searches. The results of these searches are arranged by material properties including mechanical, electrical, electromagnetic, where applicable, and fracture; and the entries are arranged in chronological order by candidate. A list, by author, follows where tabular information including charts and figures of results is given along with a brief statement of the results and conclusions. In both cases, information on the independent variables along with their range is given. The results of an extensive industry survey asking for names of other candidates on which information is lacking and also what type of service, if any, is desired in keeping a current information file on general ceramic materials.

Craft, W. J.↗

NASA NTRS1977

The influence of composition, annealing treatment, and texture on the fracture toughness of Ti-5Al-2.5Sn plate at cryogenic temperatures

The plane strain fracture toughness K sub Ic and conventional tensile properties of two commercially produced one-inch thick Ti-5Al-2.5Sn plates were determined at cryogenic temperatures. One plate was extra-low interstitial (ELI) grade, the other normal interstitial. Portions of each plate were mill annealed at 1088 K (1500 F) followed by either air cooling or furnace cooling. The tensile properties, flow curves, and K sub Ic of these plates were determined at 295 K (room temperature), 77 K (liquid nitrogen temperature), and 20 K (liquid hydrogen temperature).

Vanstone, R. H.↗

NASA NTRS1977

The effect of increased gravitational stress on bone

A group of 34 adult male chickens were chronically accelerated over an 18-week period; for the last 4 weeks the surviving animals were subjected to a 3-g field. Males of a similar weight and age were used as static controls. The objective was to evaluate the effects of an altered gravitational state on the physical properties of the tibia bone tested for torsional fracture. Of the 34 initial animals, 15 survived for the entire period and were subjected to analysis. The results suggest that the altered morphology produced by increased gravitational fields does not materially affect bone strength, at least in torsion. Decreased bone diameters were accompanied by increased cortical thickness without change in the bone resistance to torsion. The findings of increased cortical thickness with decreased bone diameter suggest reversal of the usual cellular dynamics of adult bone. Data on bone ash and density failed to reveal any substantial changes in bone mineral or organic content. Histological examination of the cortical bone did not disclose any evidence of pathology.

Riggins, R. S.↗

NASA NTRS1983

Microfissuring of Inconel 718

A tentative mathematical computer model of the microfissuring process during electron beam welding of Inconel 718 has been constructed. Predictions of the model are compatible with microfissuring tests on eight 0.25-in. thick test plates. The model takes into account weld power and speed, weld loss (efficiency), parameters and material characteristics. Besides the usual material characteristics (thermal and strength properties), a temperature and grain size dependent critical fracture strain is required by the model. The model is based upon fundamental physical theory (i.e., it is not a mere data interpolation system), and can be extended to other metals by suitable parameter changes.

Nunes, A. C., Jr.↗

NASA NTRS1994

NASA/CARES dual-use ceramic technology spinoff applications

NASA has developed software that enables American industry to establish the reliability and life of ceramic structures in a wide variety of 21st Century applications. Designing ceramic components to survive at higher temperatures than the capability of most metals and in severe loading environments involves the disciplines of statistics and fracture mechanics. Successful application of advanced ceramics material properties and the use of a probabilistic brittle material design methodology. The NASA program, known as CARES (Ceramics Analysis and Reliability Evaluation of Structures), is a comprehensive general purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. The latest version of this software, CARESALIFE, is coupled to several commercially available finite element analysis programs (ANSYS, MSC/NASTRAN, ABAQUS, COSMOS/N4, MARC), resulting in an advanced integrated design tool which is adapted to the computing environment of the user. The NASA-developed CARES software has been successfully used by industrial, government, and academic organizations to design and optimize ceramic components for many demanding applications. Industrial sectors impacted by this program include aerospace, automotive, electronic, medical, and energy applications. Dual-use applications include engine components, graphite and ceramic high temperature valves, TV picture tubes, ceramic bearings, electronic chips, glass building panels, infrared windows, radiant heater tubes, heat exchangers, and artificial hips, knee caps, and teeth.

Powers, Lynn M.↗

NASA NTRS2011

Towards Simulating a Realistic Planetary Seismic Wavefield: The Contribution of the Megaregolith and Low-Velocity Waveguides

Lunar seismograms are distinctly different from their terrestrial counterparts. The Apollo lunar seismometers recorded moonquakes without distinct P- or S-wave arrivals; instead waves arrive as a diffuse coda that decays over several hours making the identification of body waves difficult. The unusual character of the lunar seismic wavefield is generally tied to properties of the megaregolith: it consists of highly fractured and broken crustal rock, the result of extensive bombardment of the Moon. The megaregolith extends several kilometers into the lunar crust, possibly into the mantle in some regions, and is covered by a thin coating of fine-scale dust. These materials possess very low seismic velocities that strongly scatter the seismic wavefield at high frequencies. Directly modeling the effects of the megaregolith to simulate an accurate lunar seismic wavefield is a challenging computational problem, owing to the inherent 3-D nature of the problem and the high frequencies (greater than 1 Hz) required. Here we focus on modeling the long duration code, studying the effects of the low velocities found in the megaregolith. We produce synthetic seismograms using 1-D slowness integration methodologies, GEMINI and reflectivity, and a 3-D Cartesian finite difference code, Wave Propagation Program, to study the effect of thin layers of low velocity on the surface of a planet. These codes allow us generate seismograms with dominant frequencies of approximately 1 Hz. For background lunar seismic structure we explore several models, including the recent model of Weber et al., Science, 2011. We also investigate variations in megaregolithic thickness, velocity, attenuation, and seismogram frequency content. Our results are compared to the Apollo seismic dataset, using both a cross correlation technique and integrated envelope approach to investigate coda decay. We find our new high frequency results strongly support the hypothesis that the long duration of the lunar seismic codes is generated by the presence of the low velocity megaregolith, and that the diffuse arrivals are a combination of scattered energy and multiple reverberations within this layer. The 3-D modeling indicates the extreme surface topography of the Moon adds only a small contribution to scattering effects, though local geology may play a larger role. We also study the effects of the megaregolith on core reflected and converted phases and other body waves. Our analysis indicates detection of core interacting arrivals with a polarization filter technique is robust and lends the possibility of detecting other body waves from the Moon.

Schmerr, Nicholas C.↗

NASA NTRS2012

Design and Manufacturing Considerations for Shockproof and Corrosion-Immune Superelastic Nickel-Titanium Bearings for a Space Station Application

An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is a promising tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, easily lubricated and is non-magnetic. It also falls within the class of superelastic alloys and can elastically endure large strains (beyond 5 percent) making it highly resistant to excessive and unexpected (shock) loads. Key material properties and characteristics such as elastic modulus, tensile fracture sensitivity and residual stress behavior, however, differ from conventional alloys such as steel and this significantly affects bearing design and manufacturing. In this paper, the preliminary design and manufacture of ball bearings made from 60NiTi are considered for a highly corrosive, lightly loaded, low speed bearing application found inside the International Space Station s water recycling system. The information presented is expected to help guide more widespread commercialization of this new technology into space mechanism and other applications.

DellaCorte, Christopher↗

DOE OSTI2020

Machine learning for geophysical characterization of brittleness: Tuscaloosa Marine Shale case study

Brittleness is one of the most important reservoir properties for unconventional reservoir exploration and production. Better knowledge about the brittleness distribution can help to optimize the hydraulic fracturing operation and lower costs. However, there are very few reliable and effective physical models to predict the spatial distribution of brittleness. We have developed a machine learning-based method to predict subsurface brittleness by using multidiscipline data sets, such as seismic attributes, rock physics, and petrophysics information, which allows us to implement the prediction without using a physical model. The method is applied on a data set from Tuscaloosa Marine Shale, and the predicted rock physics template is close to the calculated value from conventional inverted elastic parameters. Therefore, the proposed method helps determine areas of the reservoir that have optimal geomechanical properties for successful hydraulic fracturing.

Geochemistry & Geophysics↗