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At least 145 records · Page 8

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DOE OSTI2022

Shape Evolution of C75 Large-Grain Niobium Half-Cells During Cavity Fabrication

The largely anisotropic deformation of large-grain Nb discs during deep drawing into half-cells poses a challenge for achieving a desired shape accuracy. Two 5-cell cavities for the C75 CEBAF cryomodule rework program have been fabricated at Jefferson Lab from large-grain Nb discs directly sliced from an ingot. The shape of the inner surface of eight half-cells has been inspected using a FARO Edge laser scanner during the fabrication process and compared to the reference shape. On average, approximately 63% of the half-cell inner surface was found to be within 0.1 mm of the reference shape and ~90% to be within 0.2 mm, after the final equator machining. Several 5-cell C75 cavities have also been fabricated at Research Instruments, Germany, and measurements of the shape accuracy using a Zeiss 3D coordinate measuring machine gave similar results. One half-cell was measured both at Research Instruments and Jefferson Lab for comparison.

Ciovati, G.↗

NASA NTRS1996

A Particle Representation Model for the Deformation of Homogeneous Turbulence

In simple flows, where the mean deformation rates are mild and the turbulence has time to come to equilibrium with the mean flow, the Reynolds stresses are determined by the applied strain rate. Hence in these flows, it is often adequate to use an eddy-viscosity representation. The modern family of kappa-epsilon models has been very useful in predicting near equilibrium turbulent flows, where the rms deformation rate S is small compared to the reciprocal time scale of the turbulence (epsilon/kappa). In modern engineering applications, turbulence models are quite often required to predict flows with very rapid deformations (large S kappa/epsilon). In these flows, the structure takes some time to respond and eddy viscosity models are inadequate. The response of turbulence to rapid deformations is given by rapid distortion theory (RDT). Under RDT the nonlinear effects due to turbulence-turbulence interactions are neglected in the governing equations, but even when linearized in this fashion, the governing equations are unclosed at the one-point level due to the non-locality of the pressure fluctuations.

Kassinos, S. C.↗

DOE OSTI2023

Synthetically non-Hermitian nonlinear wave-like behavior in a topological mechanical metamaterial

Topological mechanical metamaterials have enabled new ways to control stress and deformation propagation. Exemplified by Maxwell lattices, they have been studied extensively using a linearized formalism. Herein, we study a two-dimensional topological Maxwell lattice by exploring its large deformation quasi-static response using geometric numerical simulations and experiments. We observe spatial nonlinear wave-like phenomena such as harmonic generation, localized domain switching, amplification-enhanced frequency conversion, and solitary waves. We further map our linearized, homogenized system to a non-Hermitian, nonreciprocal, one-dimensional wave equation, revealing an equivalence between the deformation fields of two-dimensional topological Maxwell lattices and nonlinear dynamical phenomena in one-dimensional active systems. Our study opens a regime for topological mechanical metamaterials and expands their application potential in areas including adaptive and smart materials and mechanical logic, wherein concepts from nonlinear dynamics may be used to create intricate, tailored spatial deformation and stress fields greatly transcending conventional elasticity.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A continuum meshfree method for sandbox-style numerical modeling of accretionary and doubly vergent wedges

Here, in this study, we introduce and utilize GEOSPH, a Lagrangian particle-based continuum Smoothed Particle Hydrodynamics (SPH) code to simulate the deformation of geologic materials in sandbox-style experiments using an elastoplastic constitutive model. Due to the meshfree nature of SPH, our proposed framework is capable of handling the large deformations characteristic of sandbox-style experiments. SPH is also able to capture strain localization and discontinuities, allowing us to resolve faulting patterns emerging in the sandbox experiments. We successfully validate our SPH implementation against the benchmark experiments of Buiter and co-workers, and then apply SPH to understand the deformational processes occurring in doubly vergent orogens resultant from the S-point experimental setup and from finitely high wedge-like indenter backstops of different inclinations. We find that the topographic slope of the prowedge results from the competing processes of vertical uplift due to the indenter and forward thrusting, while the topographic slope of the retrowedge is a product of repeated shallow slope failure. Our findings show that SPH is a promising numerical method which should be added to the current palette of computational tools used by structural geologists for solving problems relating to tectonics and crustal deformation.

58 GEOSCIENCES↗

DOE OSTI2021

Revealing extreme twin-boundary shear deformability in metallic nanocrystals

Metals containing abundant coherent twin boundaries (TBs) are able to sustain substantial plastic deformation without fracture due to shear-induced TB migration and sliding. Retaining ductility in these metals, however, has proven difficult because detwinning rapidly exhausts TB migration mechanisms at large deformation, whereas TB sliding was only evidenced for loading on very specific crystallographic orientations. Here, we reveal the intrinsic shear deformability of twins in nanocrystals using in situ nanomechanical testing and multiscale simulations and report extreme shear deformability through TB sliding up to 364%. Sliding-induced plasticity is manifested for orientations that are generally predicted to favor detwinning and shown to depend critically on geometric inhomogeneities. Normal and shear coupling are further examined to delineate a TB orientation-dependent transition from TB sliding to TB cracking. These dynamic observations reveal unprecedented mechanical properties in nanocrystals, which hold implications for improving metal processing by severe plastic deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Silicon Consortium Project: No-Go on Moir Interferometry for Measuring SEI Strain as a Probe for Calendar Life Testing

Silicon is a promising candidate as a next generation anode to replace or complement graphite electrodes due to its high energy density and low lithiation potential. When silicon is lithiated, it experiences over 300% expansion which stresses the silicon as well as its solid electrolyte interphase (SEI) leading to poor performance. The use of nano-sized silicon has helped to mitigate volume expansion and stress in the silicon, yet the silicon SEI is still both mechanically and chemically unstable. Identifying the mechanical failure mechanism of the SEI will help enhance calendar and cycle life performance through improved SEI design. In situ moiré interferometry was investigated to try and track the in-plane strain in the SEI and silicon electrode for this purpose. Moiré can detect on the order of 10 nm changes in displacement and is therefore a useful tool in the measurement of strain. As the sample undergoes small deformations, large changes in the moiré fringe allow for measurements of displacement below the diffraction limit of light. Figure 1a shows how the moiré fringe changes as the sample grating deforms. As the sample contracts or expands, the frequency of the moiré fringe changes, and this change is proportional to the strain in the sample.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Island scanning pattern optimization for residual deformation mitigation in laser powder bed fusion via sequential inherent strain method and sensitivity analysis

Laser powder bed fusion (L-PBF) has emerged as one of the mainstream additive manufacturing approaches for fabricating metal parts with complex geometries and intricate internal structures. However, large deformation associated with rapid heating and cooling can lead to build failure and requires post-processing which may increase manufacturing cost and prolong the production period. Here in this work, an island scanning pattern design method is proposed to optimize the scanning direction of each island in order to reduce part deformation after cutting off the build platform. The objective of this optimization is to minimize the upward bending of the part after sectioning, which allows the part deformation to satisfy the tolerance requirement or reduce the post heat treatment time. Inherent strain method is employed in the sequential finite element analysis consisting of layer-by-layer activations and sectioning for fast residual distortion prediction. Full sequential sensitivity analysis for the formulated optimization is provided to update the island scanning directions. To show the feasibility and effectiveness of the proposed method, the scanning patterns of a block structure and a connecting rod were designed and parts were fabricated using an open architecture L-PBF machine. The fabrication experiments demonstrated that the residual deformation of both parts fabricated by optimized scanning pattern can be reduced by over 50% compared to the initial scanning patterns, which demonstrate the effectiveness of the proposed method.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Domain patterns and super-elasticity of freestanding BiFeO 3 membranes via phase-field simulations

Super-elasticity of functional ferroelectric oxides offers promises for integrating ferroelectric films into flexible electronics. However, super-elastic deformation is a complex phenomenon related to possibly multiple concurrent mechanisms. Fundamentally understanding how multiple mechanisms contribute to the super-elasticity of ferroelectric oxides is crucial to realizing their potential flexible electronic applications. In this study, we employ phase-field simulations to model the dynamics of ferroelectric domain patterns of freestanding BiFeO 3 membranes to understand the origin of their super-elasticity under substantial bending deformation (5% strain). It is demonstrated that both a reversible Rhombohedral-Tetragonal (R-T) phase transition and a nearly reversible domain evolution of BiFeO 3 membranes contribute to accommodating the large deformation and thus their super-elasticity. The dynamics of domain evolution also reveal the formation of an exotic ferroelectric vortex and polarization rotation before the phase transition. We constructed a diagram of phases and domain patterns as a function of the membrane thickness and bending angle, which allows one to readily predict the emergence of T phase and ferroelectric vortex in bent BFO membranes. These results not only provide fundamental understanding of mesoscale super-elastic mechanisms but also reveal exotic domain states of ferroelectric membranes.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Void growth in an elastic-plastic medium.

The uniaxial deformation of an elastic-plastic medium containing a doubly periodic square array of circular cylindrical voids is studied under plane-strain conditions. Both the effects of geometrical nonlinearities resulting from large deformation and physical nonlinearities arising from plastic material behavior are included in formulating the problem. A variational principle is used as the basis for implementing a finite-element solution. Results are obtained for the change in void shape and size under increasing overall strain, the overall tensile behavior of the material with voids, and the development of the plastic zone about a void.

Needleman, A.↗

NASA NTRS1991

Unified nonlinear analysis for nonhomogeneous anisotropic beams with closed cross sections

A unified methodology for geometrically nonlinear analysis of nonhomogeneous, anisotropic beams is presented. A 2D cross-sectional analysis and a nonlinear 1D global deformation analysis are derived from the common framework of a 3D, geometrically nonlinear theory of elasticity. The only restrictions are that the strain and local rotation are small compared to unity and that warping displacements are small relative to the cross-sectional dimensions. It is concluded that the warping solutions can be affected by large deformation and that this could alter the incremental stiffnes of the section. It is shown that sectional constants derived from the published, linear analysis can be used in the present nonlinear, 1D analysis governing the global deformation of the beam, which is based on intrinsic equations for nonlinear beam behavior. Excellent correlation is obtained with published experimental results for both isotropic and anisotropic beams undergoing large deflections.

Atilgan, Ali R.↗

DOE OSTI2022

Simulation of the TAEs’ saturation phase in the Large Helical Device: MHD burst

Here, the aim of the present study is to analyze the saturation regime of the toroidal Alfven eigenmodes (TAE) in the Large Helical Device plasma, particularly the MHD burst. The linear and nonlinear evolution of the TAEs are simulated by the FAR3d code that uses a reduced MHD model for the thermal plasma coupled with a gyrofluid model for the energetic particle (EP) species. The linear simulations indicate the overlapping of 1/2–1/1, 2/3–2/4 and 3/5–3/6 TAEs in the inner-middle plasma region and frequency range of 45–75 kHz, triggered by EPs with an energy of T f = 45 keV and EP β = 0.022. The nonlinear simulations show that 2/3–2/4 and 3/4–3/5 TAEs are further destabilized due to the energy transfer from the 1/1–1/2 TAE, leading to broad TAE radial overlapping and triggering of the MHD burst. The energy of the 1/1–1/2 TAE is also nonlinearly transferred to the thermal plasma destabilizing the 0/0 and 0/1 modes, inducing the generation of shear flows and zonal currents, as well as large deformations in the thermal pressure and EP density radial profiles. The nonlinear simulation reproduces the same succession of instabilities and the same frequency range with respect to the experiment. The instability propagates outward during the bursting phase, showing a large decrease of the EP density profile between the middle-outer plasma, indicating the loss of part of the EP population that explains the decrease in the plasma heating efficiency observed during the MHD burst.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗

NASA NTRSDate not supplied

Experimental Characterization of the Dimensional Stability of Deployable Composite Booms During Stowage

Thin-ply carbon fiber reinforced polymer materials offer the opportunity to create long thin-shell booms with high strength to weight ratios. These booms can be rolled up and stowed in small volumes to be later deployed. These features make them ideal for use in gossamer solar sails as well as other deployable space structures. It has been observed that stowing the booms in rolled-up configurations can cause time-dependent deformations. A comprehensive understanding of the detrimental effects of stowing the coiled booms is necessary to implement these structures in spaceflight missions. During stowage inside the spacecraft, the boom is subjected to a constant deformation/strain that causes it to relax over time, measurable by a decrease in stress. Using large deformation bending tests, the complete fold-stow-unfold-recover cycle of thin-laminate candidates for the rollable booms is characterized. Further bending and stowage testing is done at the boom level. The results from this test campaign will be used to evaluate the dimensional stability of deployable booms made from thin-ply composites that exhibit visco-elasto-plastic behavior and calibrate and validate numerical finite element models that include visco-elasto-plastic material models.

Experimental Characterization↗

NASA NTRS1971

A borehole jack for deformability, strength, and stress measurements in a 2-inch borehole

A borehole jack devised for lunar exploration is described and results of its use in simulated lunar solids are presented. A hydraulic cylinder mounted between two stiff plates acts to spread the plates apart against the borehole walls when pressured. The spreading is measured by a displacement transducer and the load is measured hydraulically. The main improvement over previous instruments is the increased stroke, which allows large deformations of the borehole. Twenty-eight pistons are used to obtain a high hydraulic efficiency, and three return pistons are also provided. Pressure-deformation curves were obtained for each test on Lunar Soil Simulant No. 2, a light gray silty basalt powder.

Goodman, R. E.↗

DOE OSTI2023

Decay spectroscopy of 160 Eu: Quasiparticle configurations of excited states and structure of K π = 4 + bandheads in 160 Gd

Background: Detailed spectroscopy of neutron-rich, heavy, deformed nuclei is of broad interest for nuclear astrophysics and nuclear structure. Nuclei in the r-process path and following freeze-out region impact the resulting r-process abundance distribution, and the structure of nuclei midshell in both proton and neutron number helps to understand the evolution of subshell gaps and large deformation in these nuclei. Purpose: We aim to improve the understanding of the nuclear structure of 160 Gd, specifically the K π = 4 + bands, as well as study the β decay of 160 Eu into 160 Gd. Methods: High-statistics decay spectroscopy of 160 Gd resulting from the β-decay of 160 Eu was collected using the GRIFFIN spectrometer at the TRIUMF-ISAC facility. Results: Two new excited states and ten new transitions were observed in 160 Gd. The β-decaying half-lives of the low- and high-spin isomers in 160 Eu were determined, and the low-spin state's half-life was measured to be t 1/2 = 26.0 (8) s, ≈ 16% shorter than previous measurements. Lifetimes of the two K π = 4 + bandheads in 160 Gd were measured for the first time, as well as γ – γ angular correlations and mixing ratios of intense transitions out of those bandheads. Conclusions: Lifetimes and mixing ratios suggest that the hexadecapole phonon model of the K π = 4 + bandheads in 160 Gd is preferred over a simple two-state strong mixing scenario, although further theoretical calculations are needed to fully understand these states. Additionally, the 1999.0-keV state in 160 Gd heavily populated in β decay is shown to have positive parity, which raises questions regarding the structure of the high-spin β-decaying state in 160 Eu.

150 ≤ A ≤ 189↗

DOE OSTI2021

Anisotropy evolution of elastomeric foams during uniaxial compression measured via in-situ X-ray computed tomography

We have characterized the three-dimensional evolution of microstructural anisotropy of a family of elastomeric foams during uniaxial compression via in-situ X-ray computed tomography. Flexible polyurethane foam specimens with densities of 136, 160 and 240 kg/m 3 were compressed in uniaxial stress tests both parallel and perpendicular to the foam rise direction, to engineering strains exceeding 70%. The uncompressed microstructures show slightly elongated ellipsoidal pores, with elongation aligned parallel to the foam rise direction. The evolution of this microstructural anisotropy during deformation is quantified based on the autocorrelation of the image intensity, and verified via the mean intercept length as well as the shape of individual pores. Trends are consistent across all three methods. In the rise direction, the material remains transversely anisotropic throughout compression. Anisotropy initially decreases with compression, reaches a minimum, then increases up to large strains, followed by a small decrease in anisotropy at the largest strains as pores collapse. Compression perpendicular to the foam rise direction induces secondary anisotropy with respect to the compression axis, in addition to primary anisotropy associated with the foam rise direction. In contrast to compression in the rise direction, primary anisotropy initially increases with compression, and shows a slight decrease at large strains. These surprising non-monotonic trends and qualitative differences in rise and transverse loading are explained based on the compression of initially ellipsoidal pores. Microstructural anisotropy trends reflect macroscopic stress-strain and lateral strain response. These findings provide novel quantitative connections between three-dimensional microstructure and anisotropy in moderate density polymer foams up to large deformation, with important implications for understanding complex three-dimensional states of deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Machine learning visualization tool for exploring parameterized hydrodynamics

We are interested in the computational study of shock hydrodynamics, i.e. problems involving compressible solids, liquids, and gases that undergo large deformation. These problems are dynamic and nonlinear and can exhibit complex instabilities. Due to advances in high performance computing it is possible to parameterize a hydrodynamic problem and perform a computational study yielding $\mathscr{O} (TB)$ of simulation state data. We present an interactive machine learning tool that can be used to compress, browse, and interpolate these large simulation datasets. This tool allows computational scientists and researchers to quickly visualize 'what-if' situations, perform sensitivity analyses, and optimize complex hydrodynamic experiments.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Room Temperature Quasi-static Characterization and Constitutive Model Parametrization of Flexible Polyurethane Foams of Different Densities Loaded in Different Orientations

This report describes the efforts to characterize and model General Plastics TF6070 and EF4000 flexible polyurethane foams under room temperature, large deformation quasi-static cyclic mechanical loading conditions. Densities from three to fifteen pound per cubic foot (PCF) are examined, which correspond to relative densities of approximately 4 to 20%. These foams are open cell structured and flexible at room temperature with a glass transition transition less than -30°C, and they fully recover their original shape when unloaded (at room temperature). Uniaxial compression tests were conducted with accompanying lateral image series for Digital Image Correlation (DIC) analysis with the goal of extracting transverse strain responses. Due to difficulties with DIC analysis at large strains, lateral strains were instead extracted for each test via edge tracking. The experimental results exhibit a nonlinear elastic response and anisotropic material behavior (particularly for the lower densities). Some hysteresis is observed that is different between the first and subsequent cycles of deformation indicating both a small degree of permanent damage (reduced stiffness during reloading) and viscoelasticity. These inelastic mechanisms are not considered in the modeling and calibration in this report. This work considers only the rate independent, room temperature foam behavior. Individual foam densities were calibrated for loading in two directions, parallel and perpendicular to the foam bubble rise direction, since the mechanical behavior is different in these two directions. The Flex Foam constitutive model was used for all parameterizations despite the fact that the model is isotropic. A review of the constitutive model is given as well as necessary data reduction procedures to parameterize it for each foam density and orientation are discussed. Finally, two different parameterizations are developed that take the undeformed foam density as an input that span all densities considered. These two parameterized models represent foams loaded in the rise and transverse directions respectively. We summarize the assumptions and limitations of the parameterizations provided in this report to guide analysis choices with them. All parameterizations presented herein have the following traits, room temperature, rate independent, damage-free, and non-dissipative . Isotropy (even if they are representing anisotropic data). Supplied Sierra Solid Mechanics Flex Foam Model Inputs are in units: pounds, inches, Celsius, and seconds

36 MATERIALS SCIENCE↗