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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Experimental data for damage mechanics simulation challenge

While there are many computational approaches for simulating damage in rock and other materials, few have been ground truth tested with either known experimental data or with blind data sets. Here, in this work, we present a bench-mark laboratory data set for a damage mechanics challenge to compare computational approaches on damage evolution in brittle-ductile materials. The samples were fabricated through additive manufacturing to produce repeatable specimens designed to fail in controlled ways. The failure was induced in the samples using a 3-point bending test to produce different Modes such as Mode I and mixed Modes including I-II, I-III and I-II-III Modes to generate a calibration data set and a blind challenge data set. Data collected included spatial and temporal measurements from traditional digital load–displacement sensors, 2D digital image correlation measurement to map surface deformations, 3D X-ray microscopy to ground-truth the crack-failure geometry, and laser profilometry to capture surface roughness. The data sets are available, on a data repository, to the community to advance computational models to improve our ability to predict damage in brittle-ductile materials.

3-point bending↗
DOE OSTI2022

Application of the Continuum Damage Mechanics Wilshire-Cano-Stewart (WCS) Model

In this study, the applications of the continuum damage mechanics-based Wilshire-Cano-Stewart (WCS) model are explored to predict rupture time, minimum-creep-strain-rate (MCSR), damage, damage evolution, and creep deformation. Increase knowledge in manufacturing methods has pushed the limit of material science and the development of new materials. Conventional testing is required to qualify materials against creep which according to the ASME B&PV III code, 10,000+ hours of experiments are necessary for each heat before materials are put into service. This process is costly and not feasible for new materials. As an alternative, models have been employed to predict creep behaviors and reduce the amount of time necessary for material qualification. Many models have been developed to predict distinct creep behaviors and the question of which model is best remains. Amongst current models, the WCS model has emerge with the ability to predict multiple behaviors using an explicit analytical approach with the ability to predict long-term creep. In this study the novel continuum damage mechanics WCS is employed in multiple applications. The goals of the study are (a) to discuss and determine the framework of the WCS model and validated it mathematically and using parametric simulations, (b) applied the model to accelerated creep data to show the capabilities of the model with non-conventional data, and (c) applied a novel numerical method, the datum temperature method (DTM) to show the model extrapolations and interpolations capabilities with limited and reduce data sets. To accomplish these goals, data is gathered for alloy P91 and Inconel 718 to develop and post-audit validate the model. The benefits of using the WCS model is that it provides an explicit stress and temperature dependency ideal for extrapolations, the coupled equations are suitable for finite element analysis (FEA) implementation, and it follows an explicit calibration approach. The model also proves that it can be applied to accelerated testing data and using the DTM.

Cano, Jaime A↗
DOE OSTI2014

The role of nickel in radiation damage of ferritic alloys

According to modern theory, damage evolution under neutron irradiation depends on the fraction of self-interstitial atoms (SIAs) produced in the form of one-dimensional glissile clusters. These clusters, having a low interaction cross-section with other defects, are absorbed mainly by grain boundaries and dislocations, creating the so-called production bias. It is known empirically that the addition of certain alloying elements influences many radiation effects, including swelling; however, the mechanisms are unknown in many cases. In this study, we report the results of an extensive multi-technique atomistic level modeling study of SIA clusters mobility in body-centered cubic Fe–Ni alloys. We have found that Ni interacts strongly with the periphery of clusters, affecting their mobility. The total effect is defined by the number of Ni atoms interacting with the cluster at the same time and can be significant, even in low-Ni alloys. Thus a 1 nm (37SIAs) cluster is practically immobile at T < 500 K in the Fe–0.8 at.% Ni alloy. Increasing cluster size and Ni content enhances cluster immobilization. Finally, this effect should have quite broad consequences in void swelling, matrix damage accumulation and radiation induced hardening and the results obtained help to better understand and predict the effects of radiation in Fe–Ni ferritic alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A dislocation-based crystal plasticity framework for dynamic ductile failure of single crystals

We developed a framework for dislocation-based viscoplasticity and dynamic ductile failure to model high strain rate deformation and damage in single crystals. The rate-dependence of the crystal plasticity formulation is based on the physics of relativistic dislocation kinetics suited for extremely high strain rates. The damage evolution is based on the dynamics of void growth, which are governed by both micro-inertia as well as dislocation kinetics and dislocation substructure evolution. Furthermore, an averaging scheme is proposed in order to approximate the evolution of the dislocation substructure in both the macroscale as well as its spatial distribution at the microscale. In addition, a concept of a single equivalent dislocation density that effectively captures the collective influence of dislocation density on all active slip systems is proposed here. Together, these concepts and approximations enable the use of semi-analytic solutions for void growth dynamics developed in [J. Wilkerson and K. Ramesh. A dynamic void growth model governed by dislocation kinetics. J. Mech. Phys. Solids, 70:262–280, 2014.], which greatly reduce the computational overhead that would otherwise be required. The resulting homogenized framework has been implemented into a commercially available finite element package, and a validation study against a suite of direct numerical simulations was carried out.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Development of Surface Grain Relief on Self-Ion Irradiated Copper

The development of surface grain relief has been observed on self-ion irradiated pure polycrystalline copper. However, the mechanistic origin of this feature has yet to be determined. Two possible mechanisms, anisotropic creep relaxation of void swelling induced stresses and crystallographic orientation-dependent sputtering rate differences, are being investigated as the cause of this evolution. This work focuses on characterizing the surface development and investigating the mechanism of orientation-dependent sputtering. Based on the conditions under which these specimens were irradiated, preferential sputtering is not likely to be the cause of the observed grain relief. Surface grain relief can greatly influence the ability to non-destructively detect irradiation-induced effects in polycrystalline metals. Determining the origin of grain relief development is necessary before this surface feature can be used an indicator of irradiation-induced effects in pure copper and other alloys. The development of surface grain relief has been observed on self-ion irradiated pure polycrystalline copper irradiated to 100 dpa. This surface feature was first noted by measuring samples using transient grating spectroscopy and later confirmed using scanning electron microscopy. Calculations of single-crystal sputtering rates show that the difference in sputtering yields between a randomly-oriented solid and a low-index plane is not sufficient to account for the observed height difference. SEM images appear to show a maximum step-height difference of around 100 nm and differential sputtering can only account for differences on the order of 10 nm at most. This determination indicates that anisotropic creep relaxation may be the mechanistic origin of the observed surface features. If this is the case, which will be confirmed by future work, then TG spectroscopy may be an effective tool for the determination of the onset of certain radiation-damage evolution. For example, if the onset of creep relaxation is strongly correlated to a specific level of void swelling and if the surface features present as a result of creep relaxation can be observed using TG spectroscopy, then accurate determinations of particular levels of void swelling may be made. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2025

Kinetic Monte Carlo simulations of aging in δ -Pu

We have developed a first-passage kinetic Monte Carlo approach for materials aging to investigate the sensitivity of void swelling to model parameters, including helium bubble density and size distribution. In addition to explicitly accounting for the spatial distribution of individual point defects, bubbles, and voids, our approach can simulate total doses equivalent to 100 years of natural aging on statistically representative volumes of materials. This technique enables us to study the effects on swelling and radiation damage evolution due to temperature and dose rate (as altered in artificially aged experiments), differences in effective interaction radii between vacancies and interstitials, and varying defect diffusion activation energies, while providing more detailed information than previous rate-equation based approaches. In conclusion, our results indicate that spatial effects that are not modeled in mean-field rate theories could play a significant role in void swelling initiation and growth for certain regimes of model parameters.

Actinides↗
DOE OSTI2020

Gas Transport in the Insensitive High Explosive PBX 9502

Small-scale laboratory experiments were performed to analyze gas transport mechanics in PBX 9502, an insensitive high explosive (IHE) composition. Two independent investigations are reported here. First, gas permeametry and dynamic pycnometry techniques were used to measure the molecular flow (Knudsen) coefficient and the internally interconnected void fraction of pristine and thermally damaged samples in two uniaxial pressing orientations. The permeability of PBX 9502 was found to be unmeasurably low (of the same order of magnitude as PTFE) with gas transport being diffusion-dominated. Secondly, a pressure vessel experiment was developed to measure quasi-static and dynamic gas generation as the explosive was heated to self-ignition (cookoff). The gas generation results and the permeability/diffusivity findings provide evidence that PBX 9502 remains impermeable until seconds prior to self-ignition. At ignition, internal void-pressure drives macro-scale cracking and the sample becomes uniformly incorporated in the following deconsolidating deflagration. These results are discussed within the context of previous observations of pressure-dependent cookoff behavior of PBX 9502 and provide a more complete description of thermal damage evolution in this explosive composition.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2017

Parameter Calibration of GTN Damage Model and Formability Analysis of 22MnB5 in Hot Forming Process

Hot forming of high strength steel at elevated temperatures is an attractive technology to achieve the lightweight of vehicle body. The mechanical behavior of boron steel 22MnB5 strongly depends on the variation of temperature which makes the process design more difficult. In this paper, the Gurson–Tvergaard–Needleman (GTN) model is used to study the formability of 22MnB5 sheet at different temperatures. Firstly, the rheological behavior of 22MnB5 is analyzed through a series of hot tensile tests at a temperature range of 600-800 °C. Then, a detailed process to calibrate the damage parameters is given based on the response surface methodology and genetic algorithm method. The GTN model together with the damage parameters calibrated is then implemented to simulate the deformation and damage evolution of 22MnB5 in the process of high-temperature Nakazima test. The capability of the GTN model as a suitable tool to evaluate the sheet formability is confirmed by comparing experimental and calculated results. Finally, as a practical application, the forming limit diagram of 22MnB5 at 700 °C is constructed using the Nakazima simulation and Marciniak–Kuczynski (M–K) model, respectively. And the simulation integrated GTN model shows a higher reliability by comparing the predicted results of these two approaches with the experimental ones.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Measurement and Simulation of Vacancy Formation in 2-MeV Self-irradiated Pure Fe

Positron annihilation spectroscopy is a powerful tool to quantify the amount of vacancies and vacancy clusters in materials. The technique has been utilized to study the induced defects in materials after ion beam and neutron irradiations. Here we make the case for how the technique can and should be utilized to quantify the defects created by irradiation in situ during irradiation to foster a more thorough understanding of the surviving defects after initial collision cascades. This paper outlines a future experimental approach and its meaning for the nuclear materials community, being able to benchmark commonly used rate theory models of damage evolution.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Compact forced simple-shear sample for studying shear localization in materials

In this paper, a new specimen geometry, the compact forced-simple-shear specimen (CFSS), has been developed as a means to achieve simple shear testing of materials over a range of temperatures and strain rates. The stress and strain state in the gage section is designed to produce essentially “pure” simple shear, mode II in-plane shear, in a compact-sample geometry. The 2-D plane of shear can be directly aligned along specified directional aspects of a material's microstructure of interest; i.e., systematic shear loading parallel, at 45°, and orthogonal to anisotropic microstructural features in a material such as the pancake-shaped grains typical in many rolled structural metals, or to specified directions in fiber-reinforced composites. Finally, the shear-stress shear-strain response and the damage evolution parallel and orthogonal to the pancake grain morphology in 7039-Al are shown to vary significantly as a function of orientation to the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Creep ductility limiting mechanisms in an additively manufactured Al-Ce-Ni-Mn-Zr alloy

Tensile creep response and cavitation damage evolution in an additively manufactured Al-7.5Ce-4.5Ni-0.4Mn-0.7Zr (wt%) alloy with peak-aging and overaging treatments were investigated in the 300–400 ºC range. Microstructural heterogeneity and its response to heat treatment and subsequent creep deformation were studied to understand the interplay between cavity formation, creep lifetime and ductility. Increasing the applied stress activated the nucleation of more cavities, an experimental observation that is well described using the vacancy accumulation model. Cavities nucleated prematurely due to localized plasticity in the denuded zones that formed at/near melt-pool or grain boundaries. Microstructure/deformation heterogeneity with consequent evolution of stress triaxiality, especially at lower stresses, causes accelerated cavitation, thus producing low creep ductility (∼ 0.2–2.4 %), compared to (∼12–21 %) ductility of the alloy measured by regular tensile tests at equivalent temperatures. A constrained diffusional cavity growth mechanism with continuous cavity nucleation during creep is established as the dominant mechanism, implying that cavitation involves vacancy diffusion, yet its growth rate is dictated by the minimum creep rate. In conclusion, the ductility-limiting creep and cavitation mechanisms discussed here provide new insight into the creep behavior of 3D-printed metallic alloys.

Additive manufacturing↗
DOE OSTI2024

A variational phase-field framework for thermal softening and dynamic ductile fracture

A variational phase field model for dynamic ductile fracture is presented. Here, the model is designed for elasto-viscoplastic materials subjected to rapid deformations in which the effects of heat generation and material softening are dominant. The variational framework allows for the consistent inclusion of plastic dissipation in the heat equation as well as thermal softening. It employs a coalescence function to degrade fracture energy during regimes of high plastic flow. A variationally consistent form of the Johnson–Cook model is developed for use with the framework. Results from various benchmark problems in dynamic ductile fracture are presented to demonstrate capabilities. In particular, the ability of the model to regularize shear band formation and subsequent damage evolution in two- and three-dimensional problems is demonstrated. Importantly, these phenomena are naturally captured through the underlying physics without the need for phenomenological criteria such as stability thresholds for the onset of shear band formation.

42 ENGINEERING↗
DOE OSTI2018

Energy dissipation in polymer-bonded explosives with various levels of constituent plasticity and internal friction

The ignition of energetic materials (EM) under dynamic loading is mainly controlled by localized temperature spikes known as hotspots. Hotspots occur due to several dissipation mechanisms, including viscoplasticity, viscoelasticity, and internal friction along crack surfaces. In this work, to analyze the contributions of these mechanisms, we quantify the ignition probability, energy dissipation, damage evolution, and hotspot characteristics of polymer-bonded explosives (PBXs) with various levels of constituent plasticity of the energetic phase and internal crack face friction. Using PBX9501 consisting of HMX (Octahydro-1,3,5,7-Tetranitro-1,2,3,5-Tetrazocine) and Estane as a reference material, we analyze variants of this material with several values of the yield stress of the energetic phase and coefficients of internal crack face friction, while other parameters are kept unchanged. The impact loading involves piston velocities between 200 and 1200 m/s. The analysis uses a Lagrangian cohesive finite element framework that explicitly accounts for finite-strain elastic-viscoplastic deformation of the grains, viscoelastic deformation of the binder, arbitrary crack initiation and propagation in the grains and the binder, debonding between the grains and the binder, contact between internal surfaces, friction and frictional heating along internal surfaces, heat generation resulting from inelastic bulk deformation, and heat conduction. To determine the ignition status of the material or “go” or “no-go” state, we use a criterion based on a criticality threshold obtained from chemical kinetics calculations. For PBX with various levels of HMX plasticity and friction, the probability of ignition, the evolution of dissipation caused by plasticity and friction, the density of cracks, and the locations of cracks are quantified. Results show that samples with higher levels of constituent plasticity (lower yield strengths) or lower levels of internal friction are less likely to ignite. The relative importance of plasticity and friction depends on load intensity, with frictional heating decreasing as load intensity increases. Although the overall viscoplastic heating outweighs the overall frictional heating, friction plays a very important role in hotspot development at all load intensities analyzed, owing to the fact that frictional heating is more localized than viscoplastic heating. Finally, the predicted thresholds and ignition probabilities are expressed in a load intensity-load duration relation for PBX with different constituent properties.

36 MATERIALS SCIENCE↗
DOE OSTI2021

TOUGH-RFPA: Coupled thermal-hydraulic-mechanical Rock Failure Process Analysis with application to deep geothermal wells

This paper presents a coupled thermal-hydraulic-mechanical (THM) model for simulating failure processes in geological media. The coupling between stress/strain and heat transfer describing how thermal expansion affects stress is based on the theory of thermo-elasticity. Additionally, the coupling between stress/strain and fluid flow describing how pore-pressure affects stress is governed by Biot's consolidation theory. Stress/strain-dependent porosity/permeability/capillary-pressure defines the influence of stress on fluid flow and thermal fields. The THM model is implemented in the solver module that links the multiphase, multicomponent fluid flow simulator TOUGH2 with the geomechanical simulator RFPA (Rock Failure Process Analysis), which is based on the concept that heterogeneity leads to non-linearity and progressive failure behavior. Capability of TOUGH-RFPA simulator was verified by two benchmark problems related to hydraulic-mechanical and thermal-mechanical response in a hollow cylinder. Then the applicability of TOUGH-RFPA was demonstrated for modeling cooling-induced damage around a very deep geothermal well with mesoscopic heterogeneous properties, which showed complex damage evolution and fracturing during well cooling and fluid pressurization.

42 ENGINEERING↗
DOE OSTI2024

A prediction model of failure threshold for shear deformation in a Zr-based bulk metallic glass

The failure of bulk metallic glasses (BMGs) during plastic deformation at room temperature is abrupt and instantaneous, while the analysis of precursor information based on avalanche events helps predict catastrophic failure. An acoustic emission (AE) signal can provide accurate precursor information for material failure, due to its sensitive and high fast calculation ability. In the current study, AE monitoring tests are carried out during uniaxial compression tests of BMGs at different strain rates. The AE experimental failure threshold, E max , is proposed on the basis of AE cumulative energy, which reflects the intensity of damage evolution at different loading conditions. Compared with the critical shear band velocity (CSBV) associated with stick-slip dynamics of serrated flow, E max is a more sensitive failure parameter since it is connected with the local microscopic changes that occur during the material response process. Here, the E max is obtained prior to reaching the CSBV since the calculation of these two avalanches analysis focuses on the different stages of shear band growth. In particular, AE events are related to the “dry” friction process in the first stage, however, the CSBV is responsible for the “viscous” glide in the second stage. Therefore, Emax is not affected by the complex interactions between the shear bands during the stick-slip process. The maximum avalanche of serrated flow, S max , is proposed as the experimental failure threshold, which depends on the applied strain rate as S max ~ $\dot{ε}$ –λ . According to the relationship of E max and S max , the theoretical failure threshold, E max , follows a criterion E max = 2545$\dot{ε}$ –λ - 4468, where λ is equivalent to 0.15 for this work. Finally, combining the different calculations and AE measurements, this model gives new insights to predict the deformation failure behavior of Zr-based BMGs.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Atomic-scale mechanisms of helium bubble hardening in iron

Generation of helium due to (n,α) transmutation reactions changes the response of structural materials to neutron irradiation. The whole process of radiation damage evolution is affected by He accumulation and leads to significant changes in the material s properties. A population of nanometric He-filled bubbles affects mechanical properties and the impact can be quite significant because of their high density. Understanding how these basic mechanisms affect mechanical properties is necessary for predicting radiation effects. In this paper we present an extensive study of the interactions between a moving edge dislocation and bubbles using atomic-scale modeling. We focus on the effect of He bubble size and He concentration inside bubbles. Thus, we found that ability of bubbles to act as an obstacle to dislocation motion is close to that of voids when the He-to-vacancy ratio is in the range from 0 to 1. A few simulations made at higher He contents demonstrated that the interaction mechanism is changed for over-pressurized bubbles and they become weaker obstacles. The results are discussed in light of post-irradiation materials testing.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Irradiation-induced defect formation and damage accumulation in single crystal CeO 2

Here, the accumulation of irradiation-induced disorder in single crystal CeO 2 has been investigated over a wide range of ion fluences. Room temperature irradiations of epitaxial CeO 2 thin films using 2 MeV Au 2+ ions were carried out up to a total fluence of 1.3 x 10 16 cm –2 Post-irradiation disorder was characterized using ion channeling Rutherford backscattering spectrometry (RBS/C) and confocal Raman spectroscopy. The Raman measurements were interpreted by means of a phonon confinement model, which employed rigid ion calculations to determine the phonon correlation length in the irradiated material. Comparison between the dose dependent changes in correlation length of the Raman measurements and the Ce disorder fraction from RBS/C provides complementary quantitative details on the rate of point and extended defect formation on the Ce and O sub-lattices over a broad range of ion fluences. Raman measurements, which are significantly more sensitive than RBS/C at low doses, reveal that the nucleation rate of defects is highest below 0.1 displacements per atom (dpa). Comparison between Raman and RBS/C measurements suggests that between 0.1 and 10 dpa the damage evolution is characterized by modest growth of point defects and/or small clusters, while above 10 dpa the preexisting defects rapidly grow into extended clusters and/or loops.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗