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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

A creep cavity growth model for creep-fatigue life prediction of a unidirectional W/Cu composite

A microstructural model was developed to predict creep-fatigue life in a (0)(sub 4), 9 volume percent tungsten fiber-reinforced copper matrix composite at the temperature of 833 K. The mechanism of failure of the composite is assumed to be governed by the growth of quasi-equilibrium cavities in the copper matrix of the composite, based on the microscopically observed failure mechanisms. The methodology uses a cavity growth model developed for prediction of creep fracture. Instantaneous values of strain rate and stress in the copper matrix during fatigue cycles were calculated and incorporated in the model to predict cyclic life. The stress in the copper matrix was determined by use of a simple two-bar model for the fiber and matrix during cyclic loading. The model successfully predicted the composite creep-fatigue life under tension-tension cyclic loading through the use of this instantaneous matrix stress level. Inclusion of additional mechanisms such as cavity nucleation, grain boundary sliding, and the effect of fibers on matrix-stress level would result in more generalized predictions of creep-fatigue life.

Kim, Young-Suk↗
DOE OSTI2019

A New Efficient Quantitative Multi-component Phase Field: Lattice Boltzmann Model for Simulating Ti6Al4V Solidified Dendrite Under Forced Flow

Ti6Al4V is a widely used, multi-component alloy in additive manufacturing, during which the fluid flow in the molten pool significantly affects the solidified dendrites. To predict and further control the microstructure, modeling and simulating the microstructure evolution play a critical role. In this study, a newly developed, efficient, quantitative multi-component phase-field (PF) model is coupled with a lattice Boltzmann (LB) model to simulate Ti6Al4V solidified dendrite evolution under fluid flow. The accuracy and convergence behavior of the model is validated by the Gibbs–Thomson relation at the dendrite tip. Single and multiple two-dimensional (2D) equiaxed dendrite evolution cases under forced flow were simulated. Results show that the dendrite pattern is influenced remarkably by the fluid flow. Underlying mechanisms of the asymmetrical evolution are revealed by discussing the interaction among the flow, composition distribution and dendrite morphology, quantitatively. The dendrite kinetics are also derived, which ascertains the relationship between tip velocity and undercooling and inlet velocity and is the foundation for larger-scale simulation. We believe that the coupled quantitative multi-component PF–LB framework employed in this study helps in investigating the solidified dendrite morphology evolution in a deep and quantitate manner.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure Characterization and Modeling for Improved Electrode Design

As part of DOE's Computer-Aided Engineering of Batteries Program, the National Renewable Energy Laboratory is developing detailed models capturing the influence of lithium-ion battery electrode design, recipe and processing on the electrode's microstructure and relating that microstructure to device-level performance. Given the difficulty in obtaining 3D microstructural images of the electrode's inert components, team member Purdue University developed an algorithm to computationally generate the so-called carbon-binder domain (CBD) for any given recipe. Mesoscale models explore the device-level impact of the CBD phase on multiple idealized and actual electrode geometries. With the inclusion of this CBD phase, microstructure models are used to predict the tortuosity of 14 different graphite and NMC electrode designs. Tortuosity predictions are shown in good agreement with experimental direct measurement and electrochemical rate studies.

25 ENERGY STORAGE↗
DOE OSTI2024

Comparison of excess free energy at an interface according to the applied interpolation scheme for elasticity: A phase-field method

Phase-field modeling is an effective simulation technique for modeling microstructure evolution of elastically anisotropic systems. To introduce the elastic energy contribution in a phase field model, an interpolation scheme is used to define the mechanical properties within the phases and across the continuous interface. Several existing interpolation schemes introduce a potential excess elastic energy at the interface, which undesirable effect on microstructure evolution needs to be evaluated. In this study, we focused on three interpolation schemes including Khachaturyan’ scheme (KHS), Voigt–Taylor’s scheme (VTS), and Steinbach–Apel’s scheme (SAS). Comparisons of these schemes’ performances were performed in three configuration types using the MOOSE (Multiphysics Object-Oriented Simulation Environment) framework: bi-crystal, isotropic particle-matrix and anisotropic particle-matrix. The contribution of excess elastic energy on the interface energy as a function of interface width and the computational time to steady-state were evaluated in these three configurations. SAS introduces the lowest excess elastic energy contribution and the VTS has the biggest contribution amongst the considered schemes. Moreover, when modeling precipitation in an anisotropic elastic material, the SAS approach seems to predict more physical convex shapes during growth, making it preferable to KHS and VTS. Finally, as currently implemented, SAS requires the largest computational time and KHS requires the smallest time to reach steady-state amongst the considered schemes.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Failure mechanisms of cross-ply carbon fiber reinforced polymer laminates under longitudinal compression with experimental and computational analyses

Here, this study investigates the failure mechanisms of cross-ply laminates subjected to longitudinal compressive loading. A sequence of failure initiation and propagation process is observed based on optical microscopy images of failed specimens. Specifically, the failure process in the cross-ply laminates involves a combination of four failure mechanisms: fiber kinking, delamination, matrix cracking, and fiber/matrix splitting. We find that the kink-bands in the middle 0° plies of the cross-ply laminates most often show a wedge shape and the angle of matrix cracks in the 90° plies is slightly larger than that of pure 90° plies. The reason has been attributed to the constraining effects by the adjacent plies. The next focus of this study is to propose hybrid micro-macro models to more systematically study the failure mechanisms of the cross-ply laminates. We show that these models accurately predict the combined failure modes of the cross-ply laminates and enable us to closely investigate the interactions of different failure mechanisms. More importantly, the hybrid models achieve great computational efficiency compared to full-scale microstructural models. Finally, the combined experimental and computational analyses presented here provide a new level of understanding of the kink-band morphology and damage mechanisms in the cross-ply laminates.

42 ENGINEERING↗
DOE OSTI2022

Multi-physics modeling of grain growth during solidification in electron beam additive manufacturing of Inconel 718

While experimental work has shown promising results regarding control of additive manufacturing metal grain structure, the effects of processing parameters on the grain structure is difficult to understand and predict from experiment alone. To this end, a modeling framework is developed which sequentially couples a macro-scale, semi-analytic thermal model, and a meso-scale, cellular automata-based microstructure model. This framework is applied to electron beam additive manufacturing of Inconel 718 using a complex spot scan pattern. The model shows that, with the same scan pattern, variations in the spot time and electron-beam current produce thermal histories with significant spatial and temporal differences, which then produce complex solidification conditions from the interplay between molten pools in the same layer and subsequent layers, resulting in vastly different grain structures. Additionally, it is noted that the framework can significantly reduce the computational expenses for coupled thermal-metallurgical problems, and has the potential to be used for component level problems.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A two-set order parameters phase-field modeling of crack deflection/penetration in a heterogeneous microstructure

Modeling of crack deflection/penetration or manifested as intergranular/transgranular fracture in polycrystals has long been a challenge in both fracture mechanics and materials science. A phase-field model formulated with two-set order parameters describing the crack field and the microstructure field respectively, is herein established to investigate the competition between crack penetration and deflection at an interface. The advantages of the proposed model are three-fold: (1) the fracture toughness of grain boundaries and/or interfaces, besides single crystal properties (e.g., Young’s modulus, Poisson ratio, and fracture toughness), can be automatically incorporated, (2) cohesive interfaces are treated in one phase-field framework in comparison with the integrated phase-field and cohesive zone model in which cohesive elements have to be manually placed at the interface, and (3) two-set order parameters enable to describe the concurrent crack propagation and microstructure evolution. The proposed model is validated by comparing the simulated critical deflection angles with the results from theoretical analysis of the linear elastic fracture mechanics and the experiments. The model is then applied to a heterogeneous Silicon Nitride polycrystal to determine the effect of interface fracture toughness on the intergranular/transgranular fracture transition and the effective toughness of the materials.

Chen, Hu↗
DOE OSTI2023

A mechanistic model for creep and thermal aging in Alloy 709

This report describes a physics-based model for creep and thermal aging in Alloy 709. Alloy 709 is an advanced austenitic alloy, targeted for use in future Sodium Fast Reactors (SFRs) and other advanced reactors. The material has superior high temperature properties compared to currently qualified 316 and 304 stainless steels. However, the available creep and thermal aging test database for Alloy 709 is significantly more limited compared to the historical materials. The physics-based model developed here is one way to accelerate the qualification of the material by providing more accurate long-term predictions for creep properties and thermal aging, compared to current empirical time-extrapolate techniques. The crystal plasticity finite element model is used to predict the deformation and failure of alloy 709. The same setup for the CPFE model is used in both the baseline model calibration process and the simulation campaigns for parameter inference. Specific constitutive choices are made for Alloy 709 to capture the primary deformation mechanisms. The dislocation creep formulation developed by Hu and Cocks is extended to account for coupled precipitation formation and the grain boundary cavitation model developed by Sham, Needleman, et al. is used to model grain boundary cavitation-induced failure. A novel update algorithm is proposed to render the semi-discrete constitutive update for the Sham-Needleman model unconditionally stable. A progressive calibration approach is adopted based on the observations that several types of material responses can be effectively decoupled. A surrogate model is trained based on full-fledged CPFE simulations to accelerate the forward model evaluations, and stochastic variational inference (SVI) is used to calibrate the unknown microstructural model parameters. The calibrated mechanistic model is used to predict the long-term creep life of Alloy 709, and the predictions are compared against classical empirical approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Combined crystal plasticity and grain boundary modeling of creep in ferritic-martensitic steels: I. Theory and implementation

This paper presents a physically-based microstructural model for creep rupture at 600 degrees °C for Grade 91 steel. The model includes constitutive equations that reflect various observed phenomena in Grade 91, and it is incorporated into a mesoscale finite element model with explicit geometry for the prior austenite grains and grain boundaries. Creep within the grains is represented using crystal plasticity for dislocation motion and recovery along with linear viscous diffusional creep for point defect diffusion. The grain boundary models include physics-based models for cavity growth and nucleation that accurately capture tertiary creep and creep rupture. Simulations of creep at 100 MPa are performed, and the contribution of each mechanism is analyzed. The overarching goal is to gain a mechanistic understanding of the material to improve the prediction of creep rupture for long service lives in elevated temperature operating conditions. The creep response of the material at different stress levels, stress states, and temperatures is studied in Part 2 of this paper in order to determine the implications of the simulations on high temperature design practice. Furthermore, the second part explores the effect of triaxial stress states on the creep response and finds a transition from notch-strengthening behavior at high stress to notch-weakening behavior at lower stresses.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Ultrasonic and micromechanical study of damage and elastic properties of SiC/RBSN ceramic composites

Ultrasonic techniques are employed to develop methods for nondestructive evaluation of elastic properties and damage in SiC/RBSN composites. To incorporate imperfect boundary conditions between fibers and matrix into a micromechanical model, a model of fibers having effective anisotropic properties is introduced. By inverting Hashin's (1979) microstructural model for a composite material with microscopic constituents the effective fiber properties were found from ultrasonic measurements. Ultrasonic measurements indicate that damage due to thermal shock is located near the surface, so the surface wave is most appropriate for estimation of the ultimate strength reduction and critical temperature of thermal shock. It is concluded that bonding between laminates of SiC/RBSN composites is severely weakened by thermal oxidation. Generally, nondestructive evaluation of thermal oxidation effects and thermal shock shows good correlation with measurements previously performed by destructive methods.

Chu, Y. C.↗
DOE OSTI2019

A new micromechanics based full field numerical framework to simulate the effects of dynamic recrystallization on the formability of HCP metals

This work presents a new full-field, efficient and mesh-free numerical framework to model microstructure evolution, dynamic recrystallization (DRX) and formability in hexagonal closed-packed (HCP) metals such as magnesium alloys at warm temperatures. A rate tangent-fast Fourier transform-based elasto-viscoplastic crystal plasticity constitutive model for HCP metals (RTCP-FFT-HCP) is coupled with a probabilistic cellular automata (CA) approach to model DRX (CA-DRX). Furthermore, this new model is coupled with the Marciniak-Kuczynski (M-K) approach to model formability of magnesium alloys at elevated temperatures. The RTCP-FFT-HCP model computes macro stress-strain, twinning volume fraction, micromechanical fields, texture evolution and local dislocation density. Nucleation of new grains and their subsequent growth is modeled using the cellular automata approach with probabilistic state switching rule. First, the proposed RTCP-FFT-HCP model is validated by comparing the predicted stress-strain responses and texture evolution under uniaxial tension and compression with experimental measurements for AZ31 sheet alloy at room temperature. The coupled CA-RTCPFFT-HCP model is further validated by comparing the predicted stress-strain responses and texture evolution in uniaxial compression with experimental measurements at 100 °C, 200 °C and 300 °C for the AZ31 sheet alloy. Next, the forming limit diagrams (FLDs) with and without including the effects of DRX are simulated at 100 °C, 200 °C and 300 °C for AZ31 sheet alloy. The predicted FLDs with DRX show very good agreement with the experimental measurements and clearly demonstrate the need for an accurate DRX model. The study reveals that the DRX strongly affects the deformed grain structure, grain size and texture evolution and also highlights the importance accounting for DRX during FLD simulations at high temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Determining Electrode Tortuosity and Rate Limitations from Experiments and Modeling

CAE models efficiently address 3D large battery performance and safety design. Further work is needed to increase electrochemical model fidelity, reduce expense of parameter ID, and integrate degradation mechanisms, enabling optimization of designs for lifetime. Microstructure models provide deeper insight into predict effective properties of macro-homogeneous models and heterogeneous utilization of electrode degradation. Enabling 10-minute fast charge of BEV200+ requires electrolytes with enhanced transport and low electrode tortuosity.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

Stress field analysis in a stony meteorite under thermal fatigue and mechanical loadings

A micromechanical approach relying on 3D image-based finite element (FE) models, together with experimental testing, is employed to investigate the stress distribution in an L6 ordinary chondrite's microstructure subjected to thermal and mechanical loadings. An in-situ X-ray micro-computed tomography (micro-CT) setup capable of applying thermal and mechanical loads shed light on crack initiation mechanisms in chondrite samples. Micro-CT images were further used to reconstruct realistic microstructural models of the samples, which were transformed into FE models using an automated non-iterative mesh generation algorithm. FE approximation of stress fields showed that under mechanical loads, the stress often concentrates in matrix-particle interfacial regions with higher curvatures. Furthermore, this could result in the nucleation and eventually propagation of cracks in such regions. However, when the thermal cycling takes place, the stress concentrates more uniformly along with particle interfaces, resulting in their debonding from the surrounding matrix. Both observations were verified by experimental data obtained from in-situ micro-CT imaging.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Physics-informed, empirically constrained machine learning for designing Fe-9Cr alloys

<span style="font-family: Calibri, sans-serif; font-size: 12pt;">Materials data analytics can be used to significantly shorten development time of specialized alloys needed for next generation energy applications. Incorporation of the domain knowledge into deep-learning graph structure via fuzzy pre-training and causal process imitation presents a viable approach to developing accurate data-driven models and reliable alloy design tools, with limited datasets. It was demonstrated that the domain knowledge-based empirical constraints not only inhibit overfitting but also allow training more accurate and reliable ML models with improved transparency of the output interpretation. In this study, alloy tensile properties were interpreted with three competing virtual-microstructure models.</span>

Romanov, Vyacheslav↗
DOE OSTI2022

Computing diffraction patterns of microstructures from phase-field simulations

The diffraction pattern of a material contains information not only on the crystal structures of its constituting phases, but also on its mesoscale spatial distributions of phases, grains, and ferroelastic, ferroelectric, and ferromagnetic domains. While diffraction patterns from experiments such as X-ray diffraction are presented in the reciprocal or Fourier space, mesoscale microstructure models such as the phase-field method naturally produce real-space images of spatial distribution of chemical composition, structural, and ferroic domains. Although one could rather readily compute the Fourier amplitudes of chemical and structural domain distributions generated by mesoscale simulations, they only contain information about the length scale and alignment of the real-space chemical and structure domains. Therefore, a direct comparison between diffraction experiments and mesoscale microstructure simulations is not possible. Here, we develop a theoretical approach to directly compute the crystal diffraction patterns of microstructures predicted by phase-field simulations. In particular, we consider five representative examples of microstructure patterns involving purely compositional domains, a single pair of tetragonal twin structures, multiple twin variants in a hexagonal system, ferroelectric polar vortices, and polycrystalline grains. The results are compared with previous experimental observations as well as X-ray diffraction experiments performed in the present study. Furthermore, the theoretical framework allows one to directly connect material microstructures and diffraction patterns predicted from phase-field simulations and the corresponding diffraction patterns from experiments, and thus providing guidance to experimental diffraction characterization and interpretation of microstructures.

36 MATERIALS SCIENCE↗
NASA NTRS1989

A Monte Carlo-finite element model for strain energy controlled microstructural evolution - 'Rafting' in superalloys

This paper presents a specialized microstructural lattice model, MCFET (Monte Carlo finite element technique), which simulates microstructural evolution in materials in which strain energy has an important role in determining morphology. The model is capable of accounting for externally applied stress, surface tension, misfit, elastic inhomogeneity, elastic anisotropy, and arbitrary temperatures. The MCFET analysis was found to compare well with the results of analytical calculations of the equilibrium morphologies of isolated particles in an infinite matrix.

Gayda, J.↗
DOE OSTI2023

Development and testing of coarse-grained models for ultrasonic simulations of cast austenitic stainless steel

Ultrasonic inspection of cast austenitic stainless steel (CASS) in the nuclear industry is particularly challenging because of sound field scatter and attenuation caused by the coarse-grained microstructure. Modeling and simulation are important tools in ultrasonic testing, as they can be used to help address key aspects of inspections, such as developing new probe designs, predicting inspection reliability, and testing phased-array focal laws. However, developing a useful and reliable CASS model is challenging due to the many grain interfaces and crystalline orientations that must be captured. We demonstrate a method of creating a realistic CASS model that is usable in CIVA, a commercially available modeling and simulation software platform. Using polished and chemically etched sections, we generate models of a coarse-grained equiaxed specimen and a columnar specimen. We also test an alternative method of generating a coarse-grained model using Voronoi regions. We qualitatively compare sound field scatter and quantitatively compare sound field attenuation and beam partitioning in simulated sound fields to those of laboratory-measured sound fields. Results show that the Voronoi models perform as well as or better than the models based on actual grain morphology. Here we also show that model-to-model randomness in Voronoi grain structure can impact the magnitude of a simulated echo response by a factor of two or more. Although CASS models are potentially a good depiction of reality for a given scenario, they should not be considered representative since CASS morphology can change significantly from specimen to specimen or within the same specimen.

36 MATERIALS SCIENCE↗