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DOE OSTI2024

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

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

36 MATERIALS SCIENCE↗

DOE OSTI2021

Scale interactions and anisotropy in Rayleigh–Taylor turbulence

We study energy scale transfer in Rayleigh–Taylor (RT) flows by coarse graining in physical space without Fourier transforms, allowing scale analysis along the vertical direction. Two processes are responsible for kinetic energy flux across scales: baropycnal work Λ, due to large-scale pressure gradients acting on small scales of density and velocity; and deformation work Π, due to multiscale velocity. Our coarse-graining analysis shows how these fluxes exhibit self-similar evolution that is quadratic-in-time, similar to the RT mixing layer. We find that Λ is a conduit for potential energy, transferring energy non-locally from the largest scales to smaller scales in the inertial range where Π takes over. In three dimensions, Π continues a persistent cascade to smaller scales, whereas in two dimensions Π rechannels the energy back to larger scales despite the lack of vorticity conservation in two-dimensional (2-D) variable density flows. This gives rise to a positive feedback loop in 2-D RT (absent in three dimensions) in which mixing layer growth and the associated potential energy release are enhanced relative to 3-D RT, explaining the oft-observed larger α values in 2-D simulations. Despite higher bulk kinetic energy levels in two dimensions, small inertial scales are weaker than in three dimensions. Moreover, the net upscale cascade in two dimensions tends to isotropize the large-scale flow, in stark contrast to three dimensions. Furthermore, our findings indicate the absence of net upscale energy transfer in three-dimensional RT as is often claimed; growth of large-scale bubbles and spikes is not due to ‘mergers’ but solely due to baropycnal work Λ.

42 ENGINEERING↗

DOE OSTI2021

Interplay Between Crustal‐Scale Thrusting, High Metamorphic Heating Rates, and the Development of Inverted Thermal‐Metamorphic Gradients: Numerical Models and Examples From the Caledonides of Northern Scotland

Abstract Understanding the processes that produce high prograde metamorphic heating rates and the development of inverted metamorphic sequences in collisional thrust belts remains a fundamental challenge for tectonics and metamorphic petrology. New 2D finite element models of crustal‐scale thrusts with variable slip rates (10, 20, 35, 50 km Myr −1 ) are used to examine how thrust sheet emplacement contributes to these processes. In the models, average prograde heating rates of 31–118 °C Myr −1 are observed in the footwall, with maximum transient heating rates of ∼167 °C Myr −1 occurring at the highest slip rate. Also, thrust sheet emplacement produces an inverted thermal gradient in the model footwall. At slip rates of 10 km Myr −1 , heating magnitudes >200 °C are observed >7 km structurally beneath the thrust plane. At slip rates of 20–50 km Myr −1 , models produce thermal penetration depths of 4–5 km for similar heating magnitudes. Petrologically determined heating rates for thrust footwalls in the Scandian orogenic wedge of northern Scotland mostly yield rates consistent with model results (10–230 °C Myr −1 ). The model‐derived magnitude of inverted thermal gradients is also similar to those indicated in texturally determined deformation temperature transects across the Scandian orogenic wedge (100 °C–180 °C). Combined, these results indicate that high heating rates can be produced by fault slip at typical plate velocities. Additionally, this implies that crustal‐scale thrusts are likely to produce inverted metamorphic sequences in most systems, provided that P‐T conditions during slip allow for metamorphic or recrystallization processes that would preserve evidence for such features.

Thigpen, J. Ryan↗

DOE OSTI2021

Microstructure and Mechanical Performance of the Friction Stir Welds Made on Neutron-Irradiated Steel with Helium

This report describes new experimental results on the microstructure and mechanical performance of the friction stir welds made on neutron-irradiated steel with helium. The report focuses on helium-related issues, specifically, helium-induced degradation in the welded joint, aiming to repair irradiated components of nuclear power plants (NPPs). The friction stir welds analyzed here were produced at Oak Ridge National Laboratory previously, and limited characterization work was performed, mostly addressing the presence or absence of macroscopic cracks. The present work attempts to perform a more comprehensive study to assess microstructure conditions, grain size, plastic strain gradients, the morphology of the helium-induced damage, and deformation behavior.

42 ENGINEERING↗

DOE OSTI2022

Shear strain gradient in Cu/Nb nanolaminates: Strain accommodation and chemical mixing

Disentangling the intragranular and interfacial plasticity contribution to the overall strain accommodation is crucial to understanding the microstructural evolution and mass transport upon deformation in materials with the nanoscale feature size. In this study, we devise a new approach to tackle the issue by introducing shear strain gradients into Cu/Nb nanolaminates of different layer thicknesses with the shear perpendicular to the laminate interfaces. The measurement of the strain gradient and the resultant lattice disorientation enables a quantitative understanding of the intragranular and interfacial plasticity contribution. We found that intragranular slip entirely governs the deformation in the 300 nm-layer laminate and, unexpectedly, contributes ~80% of the total plasticity in the 30 nm-layer laminate. The high intragranular plasticity in the thin laminate is attributed to the large width of confined slip planes and their remnant potential for storing dislocations. In addition, substantial forced chemical mixing is observed in the top region of the 30 nm-layer laminate where the effective layer thickness is reduced below 8 nm. The transition of deformation mechanism from confined layer slip to dislocation transmission is largely responsible for the initiation of substantial mixing. Our method and findings shed light on the deformation mechanism and deformation-induced mass transport behavior in nanostructured materials.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Transparent Large Strain Thermoplastic Polyurethane Magneto-Active Nanocomposites

Smart adaptive materials are an important class of materials which can be used in space deployable structures, morphing wings, and structural air vehicle components where remote actuation can improve fuel efficiency. Adaptive materials can undergo deformation when exposed to external stimuli such as electric fields, thermal gradients, radiation (IR, UV, etc.), chemical and electrochemical actuation, and magnetic field. Large strain, controlled and repetitive actuation are important characteristics of smart adaptive materials. Polymer nanocomposites can be tailored as shape memory polymers and actuators. Magnetic actuation of polymer nanocomposites using a range of iron, iron cobalt, and iron manganese nanoparticles is presented. The iron-based nanoparticles were synthesized using the soft template (1) and Sun's (2) methods. The nanoparticles shape and size were examined using TEM. The crystalline structure and domain size were evaluated using WAXS. Surface modifications of the nanoparticles were performed to improve dispersion, and were characterized with IR and TGA. TPU nanocomposites exhibited actuation for approximately 2wt% nanoparticle loading in an applied magnetic field. Large deformation and fast recovery were observed. These nanocomposites represent a promising potential for new generation of smart materials.

Yoonessi, Mitra↗

DOE OSTI2023

Effect of the neutral beam injector operational regime on the Alfven eigenmode saturation phase in DIII-D plasma

The aim of this study is to analyze the effect of the neutral beam injector (NBI) operation regime on the saturation phase of the Alfven Eigenmodes (AEs) in DIII-D plasma. Here, the analysis is done using the linear and nonlinear versions of the gyro-fluid code FAR3d. A set of parametric analyses are performed modifying the nonlinear simulation EP $β$ (NBI injection power), EP energy (NBI voltage) and the radial location of the EP density profile gradient (NBI radial deposition). The analysis indicates a transition from the soft (local plasma relaxation) to the hard MHD (global plasma relaxation) limit if the simulation EP $β$ $\unicode{x2A7E}$ $0.02$, leading to bursting MHD activity caused by radial AEs overlapping. MHD bursts cause an enhancement of the EP transport showing ballistic-like features as avalanche-like events. Simulations in the soft MHD limit show an increment of the EP density gradient as the EP $β$ increases. On the other hand, there is a gradient upper limit in the hard MHD limit, consistent with the critical-gradient behavior. AEs induce shear flows and zonal current leading to the deformation of the flux surfaces and the safety factor profile, respectively, particularly strong for the simulation in the hard MHD limit. Simulations in the hard MHD regime show a decrease of the AE frequency in the saturation phase; this is caused by the destabilization of a transitional mode between a $9/3-10/3$ TAE and a $9/3$ RSAE that may explain the AE frequency down-sweeping observed in some DIII-D discharges. Reducing the EP energy in the nonlinear simulations leads to a weakening of the plasma perturbation. On the other hand, increasing the EP energy causes the opposite effect. Nonlinear simulations of off-axis NBI profiles indicate a lower plasma perturbation as the EP density gradient is located further away from the magnetic axis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Strain Gradient Elasticity in SrTiO 3 Membranes: Bending versus Stretching

Young’s modulus determines the mechanical loads required to elastically stretch a material and also the loads required to bend it, given that bending stretches one surface while compressing the opposite one. Flexoelectric materials have the additional property of becoming electrically polarized when bent. The associated energy cost can additionally contribute to elasticity via strain gradients, particularly at small length scales where they are geometrically enhanced. Here, we present nanomechanical measurements of freely suspended SrTiO 3 crystalline membrane drumheads. In this work, we observe an unexpected nonmonotonic thickness dependence of Young’s modulus upon small deflections. Furthermore, the modulus inferred from a predominantly bending deformation is three times larger than that of a predominantly stretching deformation for membranes thinner than 20 nm. In this regime we extract a strain gradient elastic coupling of ~2.2 μN, which could be used in new operational regimes of nanoelectro-mechanics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A parallel discrete dislocation dynamics/kinetic Monte Carlo method to study non-conservative plastic processes

Non-conservative processes play a fundamental role in plasticity and are behind important macroscopic phenomena such as creep, dynamic strain aging, loop raft formation, etc. In the most general case, vacancy-induced dislocation climb is the operating unit mechanism. While dislocation/vacancy interactions have been modeled in the literature using a variety of methods, the approaches developed rely on continuum descriptions of both the vacancy population and its fluxes. However, there are numerous situations in physics where point defect populations display heterogeneous concentrations and/or non-smooth kinetics. Here, a kinetic Monte Carlo (kMC) approach for modeling vacancy transport in response to arbitrary stress fields is used. Vacancies are treated as point particles and are coupled to the dislocation substructure representing a deformed material via an advection term defined by the local stress gradients. The stress fields and the dislocation substructure are evolved using a discrete dislocation dynamics (DDD) module. To extend the coupled model to the treatment of large systems, we have implemented it in the massively-parallel DDD code ParaDiS. To avoid numerical incompatibilities associated with merging deterministic (DDD) and stochastic (kMC) integration algorithms, we cast the entire elasto-plastic-diffusive problem within a single stochastic framework, taking advantage of a parallel kMC algorithm to evolve the system as a single event-driven process. The large-scale implementation enables the study of the evolution of a variety of dislocation-defect scenarios governed by non-conservative transport kinetics. After carrying out an exhaustive numerical and computational analysis of our parallel algorithm, we show results that emphasize situations where inhomogeneous vacancy dynamics are of relevance, and compare discrete kinetics to continuum solutions for several cases.

36 MATERIALS SCIENCE↗

DOE OSTI2020

A micromirror array with annular partitioning for high-speed random-access axial focusing

Dynamic axial focusing functionality has recently experienced widespread incorporation in microscopy, augmented/virtual reality (AR/VR), adaptive optics and material processing. However, the limitations of existing varifocal tools continue to beset the performance capabilities and operating overhead of the optical systems that mobilize such functionality. The varifocal tools that are the least burdensome to operate (e.g. liquid crystal, elastomeric or optofluidic lenses) suffer from low (≈100 Hz) refresh rates. Conversely, the fastest devices sacrifice either critical capabilities such as their dwelling capacity (e.g. acoustic gradient lenses or monolithic micromechanical mirrors) or low operating overhead (e.g. deformable mirrors). Here, we present a general-purpose random-access axial focusing device that bridges these previously conflicting features of high speed, dwelling capacity and lightweight drive by employing low-rigidity micromirrors that exploit the robustness of defocusing phase profiles. Geometrically, the device consists of an 8.2 mm diameter array of piston-motion and 48-μm-pitch micromirror pixels that provide 2π phase shifting for wavelengths shorter than 1100 nm with 10–90% settling in 64.8 μs (i.e., 15.44 kHz refresh rate). The pixels are electrically partitioned into 32 rings for a driving scheme that enables phase-wrapped operation with circular symmetry and requires <30 V per channel. Optical experiments demonstrated the array’s wide focusing range with a measured ability to target 29 distinct resolvable depth planes. Overall, the features of the proposed array offer the potential for compact, straightforward methods of tackling bottlenecked applications, including high-throughput single-cell targeting in neurobiology and the delivery of dense 3D visual information in AR/VR.

42 ENGINEERING↗

NASA NTRS1973

Aircraft wake dissipation by sinusoidal instability and vortex breakdown.

Sinusoidal instability of aircraft trailing vortices was induced by differentially oscillating inboard and outboard flaps on a model wing in a ship towing tank. Measured amplification rates qualitatively agree with theoretical predictions. Axial velocities in the vortex core were directed towards the wing and measured to be approximately 25% of the tow speed. Vortex breakdown was observed to occur along trailers undergoing sinusoidal instability near but ahead (towards the wing) of positions of maximum trailer separation. It is shown that axisymmetric pressure gradients are imposed along the vortex core by the other sinusoidally deformed trailer and are responsible for the observed changes in core diameter. A theoretical model predicts the short-time behavior of the vortex core and shows that the response of the vortex depends crucially on the axial velocity in the vortex.

Bilanin, A. J.↗

NASA NTRS1980

Accuracy potentials for large space antenna structures

The relationships among materials selection, truss design, and manufacturing techniques in the interest of surface accuracies for large space antennas are discussed. Among the antenna configurations considered are: tetrahedral truss, pretensioned truss, and geodesic dome and radial rib structures. Comparisons are made of the accuracy achievable by truss and dome structure types for a wide variety of diameters, focal lengths, and wavelength of radiated signal, taking into account such deforming influences as solar heating-caused thermal transients and thermal gradients.

Hedgepeth, J. M.↗

NASA NTRS2000

Topographic Phase Recovery from Stacked ERS Interferometry and a Low-Resolution Digital Elevation Model

A hybrid approach to topographic recovery from ERS interferometry is developed and assessed. Tropospheric/ionospheric artifacts, imprecise orbital information, and layover are key issues in recovering topography and surface deformation from repeat-pass interferometry. Previously, we developed a phase gradient approach to stacking interferograms to reduce these errors and also to reduce the short-wavelength phase noise (see Sandwell arid Price [1998] and Appendix A). Here the method is extended to use a low-resolution digital elevation model to constrain long-wavelength phase errors and an iteration scheme to minimize errors in the computation of phase gradient. We demonstrate the topographic phase recovery on 16-m postings using 25 ERS synthetic aperture radar images from an area of southern California containing 2700 m of relief. On the basis of a comparison with 81 GPS monuments, the ERS derived topography has a typical absolute accuracy of better than 10 m except in areas of layover. The resulting topographic phase enables accurate two-pass, real-time interferometry even in mountainous areas where traditional phase unwrapping schemes fail. As an example, we form a topography-free (127-m perpendicular baseline) interferogram spanning 7.5 years; fringes from two major earthquakes and a seismic slip on the San Andreas Fault are clearly isolated.

Sandwell, David T.↗

NASA NTRS2022

A Numerical Study of the Liquid Motion in Titan’s Subsurface Ocean

An ocean filled with liquid water lies beneath the icy surface of several Jovian and Saturnian moons. In such an ocean, the currents are driven by various phenomena such as the tidal forcing, the deformation of the ice shell lying at its top, the temperature gradient resulting from the surface and bottom heat fluxes…The flow induced by the first two forcings can be modelled by means of a 2D depth-averaged model, while the third one generates horizontal and vertical density variations whose effects can only be captured by a 3D baroclinic model. We study the tides of Titan’s subsurface ocean and the impact of the ice shell on the liquid motion by means of the Second-generation Louvain-la-Neuve Ice–ocean Model, SLIM (https://www.climate.be/slim). The impact of the ice shell lying at the top of the ocean is modelled by a surface friction term and surface pressure terms. The latter are a function of the difference between the ocean elevation and the vertical displacement of the shell and the time derivative of this difference. Because of Titan’s appreciable obliquity (0.306°), the tidal motion expected (and found) is similar to the Europa tidal scenario described by Tyler (2008): the surface elevation consists of two bulges rotating around Titan and the associated depth-averaged velocity field consists of two gyres, separated by an area of high speed flow, whose centre follows a sinusoidal path centred on the equator. The ice shell damps the surface motion, thus slowing down the flow, without significantly modifying the spatial patterns of these fields. The depth of the ocean and the mechanical characteristics of the ice shell being poorly constrained, a sensitivity analysis is conducted. The depth-averaged flow slows down when the depth is increased and a lag appears in the tidal phase but the tidal range remains similar. The ice shell mechanical characteristics influences both the elevation and depth-averaged velocity fields in terms of magnitude but does not modify the spatial patterns of these fields. The influence of the surface heat flux is studied by means of the 3D baroclinic version of SLIM. The heat flux derived from Titan’s topography by Kvorka et al. (2018) is used as surface boundary condition for the temperature equation while a uniform bottom heat flux is implemented. Its value is computed assuming that the heat budget of the ocean is at equilibrium. These boundary conditions cause density variations, which impact the hydrodynamics of the ocean. While the flow velocity induced by these variations is two orders of magnitude smaller than the tidal flow, its orientation is time-independent, hence impacting the orientation of the velocity field. Although the variations of ocean surface elevation and speed with respect to the shell mechanical properties can be larger than those induced by the surface heat flux, taking into account the latter results in large variations of the velocity field global patterns, which was not observed when modifying the shell mechanical properties. Future studies should therefore focus on modelling the surface and bottom heat fluxes while uncertainties about the mechanical characteristics of the shell can be tolerated.

Titan↗

DOE OSTI2021

HFIR SiC-SiC Composite Clad Tube Bowing Test: Pre-Irradiation Characterization

This report describes the pre-irradiation characterization of the SiC-SiC composite clad tube bowing experiment that will be irradiated in the High Flux Isotope Reactor (HFIR). There are concerns that SiCSiC fuel cladding in light water reactors could undergo bowing because of the non-uniform fast neutron flux profiles. This experiment is combined with the SiC-SiC channel box experiment, which has similar concerns regarding control blade movements in boiling water reactors. The HFIR experiment aims to validate the predicted deformation and stresses in the composite clad specimen after the exposure of fast neutron flux gradients. Significant radial fast neutron flux gradients that exist in the permanent reflector of HFIR were thoroughly characterized by using detailed 3D neutronic calculations. The 3D displacement damage dose rate profile and the resulting volumetric swelling in SiC were used as inputs to structural analyses to determine the predicted deformation that will affect the specimens. The tube specimens were characterized by using traditional dimensional inspection and surface profilometry to provide detailed information regarding the pre-irradiation condition as the first step to evaluate the radiation-induced deformation. Furthermore, fine engraving markers were inscribed along all outer surfaces of the specimen and mapped by using a digital microscope and a multidimensional stage. This allows marker spacings to be accurately measured and compared with similar measurements that will be made post-irradiation to provide local radiation-induced strain mapping. The experiment successfully completed two HFIR cycle irradiations, cycles 492 and 493, which finished on July 25, 2021.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1985

Deformation of the heliospheric current sheet

A kinematic analysis of the previously neglected effect of velocity inhomogeneity on the topology of the heliospheric current sheet in a radially flowing solar wind shows how the originally smooth current sheet becomes 'ruffled'. In the highly idealized case of a totally uniform, radial, steady solar wind, the shape of the current sheet is independent of distance from the sun. However, the real solar wind is inhomogeneous; the velocity varies from point to point along the current sheet, causing a distortion in the current sheet of progressively greater amplitude with increasing distance from the sun. This is true even for purely radial flow. Significant and observable distortion is produced by relatively small gradients in velocity; thus to predict or understand the shape of the heliospheric current sheet it is essential to know the solar wind in which the current sheet is embedded. Examples are given of mild velocity gradients which demonstrate the principles, the magnitude, and the character of the effect; deformation of the actual heliospheric current sheet in the highly variable solar wind is expected to be of far greater amplitude and complexity than in the simplified, tutorial examples. A new expression for the inclination of the current sheet as a function of velocity inhomogeneity and distance from the sun that is easily applied to the interpretation of solar wind data is also derived.

Suess, S. T.↗

DOE OSTI2021

Guiding center and gyrokinetic orbit theory for large electric field gradients and strong shear flows

The guiding center and gyrokinetic theory of magnetized particle motion is extended to the regime of large electric field gradients perpendicular to the magnetic field. A gradient in the electric field directly modifies the oscillation frequency and causes the Larmor orbits to deform from circular to elliptical trajectories. In order to retain a good adiabatic invariant, there can only be strong dependence on a single coordinate at lowest order, so that resonances do not generate chaotic motion that destroys the invariant. When the gradient across magnetic flux surfaces is dominant, the guiding center drift velocity becomes anisotropic in response to external forces and additional curvature drifts must be included. The electric polarization density remains gyrotropic, but both the polarization and magnetization are modified by the change in gyrofrequency. The theory can be applied to shear flows that are even stronger than those observed in the edge transport barrier of a high-performance tokamak (H-mode) pedestal, even if the toroidal field is as small as or even smaller than the poloidal field. Yet, the theory retains a mathematical form that is similar to the standard case and can readily be implemented within existing simulation tools.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Heterogeneous microstructural evolution during hydrodynamic penetration of a high-velocity copper microparticle impacting copper

Microparticle hydrodynamic penetration (HDP) may be associated with the erosion regime in cold spray processing and other high-velocity impact events. Here, in an experimental approach where we can individually launch particles and study the impact sites, we explore copper microparticles impacted on copper substrates at velocities above 900 m/s where HDP begins. We lift cross-sectional lamellae from the impact sites with a focused-ion beam for further microstructural characterization using electron backscatter diffraction and scanning transmission electron microscopy. Due to the gradients of strain, strain rate, and temperature associated with HDP, heterogeneous microstructures result. The structural evolution processes observed include deformation twinning and multiple dislocation-mediated grain recrystallization mechanisms—geometric dynamic recrystallization (gDRX), discontinuous DRX (dDRX), and meta DRX (mDRX). The higher strains at the interface lead to the most significant structural changes and complex mechanisms. In contrast, there is a gradient to more conventional dislocation plasticity away from the interface (on either the particle or substrate side). Here, these microstructural observations are consistent with the deformation map for copper and extend the observations of impact-induced recrystallization across new regimes of behavior.

Cold spray process↗