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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 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Fabrication of microchannels in fused silica using femtosecond Bessel beams

Extended birefringent waveguiding microchannels up to 15 mm long were created inside fused silica by single-pulse irradiation with femtosecond Bessel beams. The birefringent refractive index change of 2–4 × 10{sup −4} is attributed to residual mechanical stress. The microchannels were chemically etched in KOH solution to produce 15 mm long microcapillaries with smooth walls and a high aspect ratio of 1:250. Bessel beams provide higher speed of material processing compared to conventional multipulse femtosecond laser micromachining techniques and permit simple control of the optical axis direction of the birefringent waveguides, which is important for practical applications [Corrielli et al., “Rotated waveplates in integrated waveguide optics,” Nat. Commun. 5, 4249 (2014)].

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1993

External stress-corrosion cracking of a 1.22-m-diameter type 316 stainless steel air valve

An investigation was conducted to determine the cause of the failure of a massive AISI Type 316 stainless steel valve which controlled combustion air to a jet engine test facility. Several through-the-wall cracks were present near welded joints in the valve skirt. The valve had been in outdoor service for 18 years. Samples were taken in the cracked regions for metallographic and chemical analyses. Insulating material and sources of water mist in the vicinity of the failed valve were analyzed for chlorides. A scanning electron microscope was used to determine whether foreign elements were present in a crack. On the basis of the information generated, the failure was characterized as external stress-corrosion cracking. The cracking resulted from a combination of residual tensile stress from welding and the presence of aqueous chlorides. Recommended countermeasures are included.

Moore, Thomas J.↗
DOE OSTI2017

Characterization and modeling of microstructural stresses in alumina

Brittle failure is often influenced by difficult to measure and variable microstructure–scale stresses. Recent advances in photoluminescence spectroscopy (PLS), including improved confocal laser measurement and rapid spectroscopic data collection have established the potential to map stresses with microscale spatial resolution (< 2 μm). Advanced PLS was successfully used to investigate both residual and externally applied stresses in polycrystalline alumina at the microstructure scale. The measured average stresses matched those estimated from beam theory to within one standard deviation, validating the technique. Modeling the residual stresses within the microstructure produced qualitative agreement in comparison with the experimentally measured results. In conclusion, microstructure scale modeling is primed to take advantage of advanced PLS to enable its refinement and validation, eventually enabling microstructure modeling to become a predictive tool for brittle materials.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructural Modeling of Brittle Materials for Enhanced Performance and Reliability.

Brittle failure is often influenced by difficult to measure and variable microstructure-scale stresses. Recent advances in photoluminescence spectroscopy (PLS), including improved confocal laser measurement and rapid spectroscopic data collection have established the potential to map stresses with microscale spatial resolution (%3C2 microns). Advanced PLS was successfully used to investigate both residual and externally applied stresses in polycrystalline alumina at the microstructure scale. The measured average stresses matched those estimated from beam theory to within one standard deviation, validating the technique. Modeling the residual stresses within the microstructure produced general agreement in comparison with the experimentally measured results. Microstructure scale modeling is primed to take advantage of advanced PLS to enable its refinement and validation, eventually enabling microstructure modeling to become a predictive tool for brittle materials.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Modeling Creep-Induced Stress Relaxation at the Leading Edge of SiC/SiC Airfoils

Anticipating the implementation of advanced SiC/SiC composites into internally cooled airfoil components within the turbine section of future aero-propulsion engines, the primary objective of this study was to develop physics-based analytical and finite-element modeling tools to predict the effects of composite creep and stress relaxation at the airfoil leading edges, which will generally experience large thermal gradients at high temperatures. A second objective was to examine how some advanced NASA-developed SiC/SiC systems coated with typical EBC materials would behave as leading edge materials in terms of long-term steady-state operating temperatures. Because of the complexities introduced by mechanical stresses inherent in internally cooled airfoils, a simple cylindrical thin-walled tube model subjected to thermal stresses only is employed for the leading edge, thereby obtaining a best-case scenario for the material behavior. In addition, the SiC/SiC composite materials are assumed to behave as isotropic materials with temperature-dependent viscoelastic creep behavior as measured in-plane on thin-walled panels. Key findings include: (1) without mechanical stresses and for typical airfoil geometries, as heat flux is increased through the leading edge, life-limiting tensile crack formation will occur first in the hoop direction on the inside wall of the leading edge; (2) thermal gradients through all current SiC/SiC systems should be kept below approx.300 F at high temperatures to avoid this cracking; (3) at temperatures near the maximum operating temperatures of advanced SiC/SiC systems, thermal stresses induced by the thermal gradients will beneficially relax with time due to creep; (4) although stress relaxation occurs, the maximum gradient should still not exceed 300oF because of residual tensile stress buildup on the airfoil outer wall during cool-down; and (5) without film cooling and mechanical stresses, the NASA-developed N26 SiC/SiC system with thru-thickness Sylramic-iBN fiber reinforcement and a typical EBC coating has the potential of offering a maximum long-term steady-state operating temperature of approx.3100 F at the surface of the EBC.

Lang, Jerry↗
NASA NTRS2018

Weibull-Based Stochastic Simulation of Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC (Micromechanics Analysis Code/Generalized Method of Cells) multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button-sized disk-shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300 degrees Centigrade to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

Residual Tensile Stress↗
NASA NTRS2018

Simulation of Stochastic Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis–Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button–sized disk–shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300oC to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

residual tensile stress↗
DOE OSTI2020

Analysis of chemical stress and the propensity for cracking during the vertical Bridgman growth of BaBrCl:Eu

Computational models are employed to analyze residual chemical stresses arising from compositional variations in europium-doped BaBrCl crystals grown by the vertical Bridgman method. We find that significant chemical stress is produced by radial segregation of Eu in this system. In particular, the distribution of normal stresses is set by the radial concentration gradient, whose changing sign produces surface states in tension or compression. Additionally, crack opening from surface flaws will be promoted or suppressed by tensile or compressive surface stresses, respectively. Thus, crystal growth processing strategies that change the radial dopant concentration gradients are posited to affect the propensity for cracking. For this system, surface stresses are changed from states of tension to compression when the growth rate is increased, thus improving the chances to avoid cracking—a strategy that defies classical wisdom that dictates slower growth to improve outcomes. Similar strategies affecting segregation may prove beneficial to tailor chemical stress fields to reduce cracking in other crystal growth systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1967

Glass bead shot peening retards stress corrosion failure of titanium tanks

Rigidly controlled shot peening retards the incompatibility between titanium alloys and nitrogen tetroxide in rocket-propellant storage tanks. This sets up a residual compressive stress in the surface of a material which reduces tensile stresses in the material fibers, alleviating stress corrosion.

Bales, T. T.↗
DOE OSTI2019

Bending Nanoindentation and Plasticity Noise in FCC Single and Polycrystals

We present a high-throughput nanoindentation study of in situ bending effects on incipient plastic deformation behavior of polycrystalline and single-crystalline pure aluminum and pure copper at ultranano depths (< 200 nm). We find that hardness displays a statistically inverse dependence on in-plane stress for indentation depths smaller than 10 nm, and the dependence disappears for larger indentation depths. In contrast, plastic noise in the nanoindentation force and displacement displays statistically robust noise features, independently of applied stresses. Our experimental results suggest the existence of a regime in Face Centered Cubic (FCC) crystals where ultranano hardness is sensitive to residual applied stresses, but plasticity pop-in noise is insensitive to it.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Advanced Gear Alloys for Ultra High Strength Applications

Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.

Shen, Tony↗
NASA NTRS1991

The influences of fluorine and process variations on polysilicon film stress and MOSFET hot carrier effects

The use of fluorinated gate oxides may provide an improvement in nMOSFET reliability by enhancing hot carrier resistance. In order to clarify the mechanisms by which polysilicon processing and fluorination influence the oxide behavior, a matrix of nMOSFET structures was prepared using various processing, doping, and implantation strategies. These structures were evaluated for crystalline morphology and chemical element distribution. Mechanical stress measurements were taken on the polysilicon films from room temperature to cryogenic temperature. These examinations showed that fluorination of a structure with randomly oriented polysilicon can reduce residual mechanical stress and improve hot carrier resistance at room temperature.

Lowry, Lynn E.↗
NASA NTRS1981

Analysis of Barkhausen noise to assess shrink fit stresses

The possible application of Barkhausen Noise Analysis to assess shrink fit stresses in steel bushings was investigated. Ten specimens of four different size NAS steel bushings were used in experiments to determine the relationship between the Barkhausen signal amplitude and the hoop-stress in the bushings. This relationship was investigated for specimens which were loaded by a simple clamping fixture and specimens subjected to actual thermal interference fits. The results show that while the relationship of Barkhausen signal amplitude to hoop stress is predictable for specimens loaded by the simple clamping fixture, the relationship was less predictable for actual thermal fit bushings. The variation in results could possibly be due to variable levels of axial stress produced by the differential thermal expansion of the steel and aluminum.

Nondestructive testing↗
NASA NTRS1988

Composite transport wing technology development

The design, fabrication, testing, and analysis of stiffened wing cover panels to assess damage tolerance criteria are discussed. The damage tolerance improvements were demonstrated in a test program using full-sized cover panel subcomponents. The panels utilized a hard skin concept with identical laminates of 44-percent 0-degree, 44-percent plus or minus 45-degree, and 12-percent 90-degree plies in the skins and stiffeners. The panel skins were impacted at midbay between the stiffeners, directly over the stiffener, and over the stiffener flange edge. The stiffener blades were impacted laterally. Impact energy levels of 100 ft-lb and 200 ft-lb were used. NASTRAN finite-element analyses were performed to simulate the nonvisible damage that was detected in the panels by nondestructive inspection. A closed-form solution for generalized loading was developed to evaluate the peel stresses in the bonded structure. Two-dimensional delamination growth analysis was developed using the principle of minimum potential energy in terms of closed-form solution for critical strain. An analysis was conducted to determine the residual compressive stress in the panels after impact damage, and the analytical predictions were verified by compression testing of the damaged panels.

Madan, Ram C.↗
DOE OSTI2023

Tuning Film Stresses for Open-Air Processing of Stable Metal Halide Perovskites

Challenges to upscaling metal halide perovskites (MHPs) include mechanical film stresses that accelerate degradation, dominate at the module scale, and can lead to delamination or fracture. In this work, we demonstrate open-air blade coating of single-step coated perovskite as a scalable method to control residual film stress after processing and introduce beneficial compression in the thin film with the use of polymer additives such as gellan gum and corn starch. The optoelectronic properties of MHP films with compression are improved with higher photoluminescence yields. MHP film stability is significantly improved under compression, under humidity, heat, and thermal cycling. By measuring the evolution of film stresses, we demonstrate for the first time that stress relaxation occurs in MHP films with tensile stress that correlates with film degradation. Finally, this discovery of a new mechanism underpinning MHP degradation shows that film stress can be used as a parameter to screen MHP devices and modules for quality control before deployment as a design for reliability criterion.

14 SOLAR ENERGY↗
NASA NTRS2016

Mirrors for High Resolution X-Ray Optics---Figure Preserving IR/PT Coating

Coating stress of 10 - 20 nm of Ir is sufficiently high to distort the figure of arc-second thin lightweight mirrors. For iridium: --Stress sigma ~ 4 GPa for 15 nm film implies 60 Nm integrated stress-- Need less than 3 N/m (or stress less than 200 MPa) for sub-arcsecond optics. Basic Approaches for Mitigation. A. Annealing the film-- Glass can be heat up to 400 C without distortion. Silicon is even more resistant.-- It was found that recovery is limited by residual thermal stress from taking the mirror down from high T. B. Coating bi-layer films with compressive stress with tensile stress. C. Front-and-back coating with magnetron sputtering or atomic layer deposition-- Sputtering involve spanning of substrates. Geometric difference in setup (convexness/concaveness of curved mirrors) does not permit precise front-and-back matching-- Atomic layer deposition can provide a uniform deposition front and back simultaneously.

MIRRORS FOR HIGH RESOLUTION X-RAY OPTICS↗