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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 145 records · Page 8

In-phase thermomechanical fatigue mechanisms in an unidirectional SCS-6/Ti 15-3 MMC

The objective of this investigation was to identify the inelastic deformation and damage mechanisms under in-phase (IP) thermomechanical fatigue (TMF) in a unidirectional SCS-6/Ti 15-3 metal matrix composite (MMC). Load-controlled IP TMF tests were conducted at 300-538 C at various stress ranges in high-purity argon. A major emphasis of this work was to identify damage mechanism well before final fracture of specimens, rather than to generate life diagrams, to aid development of a realistic deformation/damage and life model.

Newaz, Golam M.↗

Quasi-Static 3-Point Reinforced Carbon-Carbon Bend Test and Analysis for Shuttle Orbiter Wing Leading Edge Impact Damage Thresholds

Static 3-point bend tests of Reinforced Carbon-Carbon (RCC) were conducted to failure to provide data for additional validation of an LS-DYNA RCC model suitable for predicting the threshold of impact damage to shuttle orbiter wing leading edges. LS-DYNA predictions correlated well with the average RCC failure load, and were good in matching the load vs. deflection. However, correlating the detectable damage using NDE methods with the cumulative damage parameter in LS-DYNA material model 58 was not readily achievable. The difficulty of finding internal RCC damage with NDE and the high sensitivity of the mat58 damage parameter to the load near failure made the task very challenging. In addition, damage mechanisms for RCC due to dynamic impact of debris such as foam and ice and damage mechanisms due to a static loading were, as expected, not equivalent.

Fasanella, Edwin L.↗

ANSI/AIAA S-081A, Pressure Vessel Standards Implementation Guidelines

The stress rupture specification for Composite Overwrapped Pressure Vessels (COPV) is discussed. The composite shell of the COPV shall be designed to meet the design life considering the time it is under sustained load. A Mechcanical Damage Control Plan (MDCP) shall be created and implemented that assures the COPV will not fail due to mechanical damage due to manufacturing, testing, shipping, installation, or flight. Proven processes and procedures for fabrication and repair shall be used to preclude damage or material degradation during material processing, manufacturing operations, and refurbushment.Selected NDI techniques for the liner and/or boss(es) shall be performed before overwrapping with composite. When visual inspection reveals mechanical damage or defects exceeding manufacturing specification levels (and standard repair procedures), the damaged COPV shall be submitted to a material review board (MRB) for disposition. Every COPV shall be subjected to visual and other non-destructive inspection (NDI), per the inspection plan.

Greene, Nathanael J.↗

Prioritizing Uncertainties in Hydrogen Contribution to Risk in Post-Crash Outcomes for Rail

This report presents analysis from Sandia National Laboratories predicting contributions to risk associated with the use of hydrogen technology for rail. Event sequence diagrams are used to describe possible accident scenarios and progressions. Initiating event frequencies and branch event probabilities for each scenario are quantified with uncertainty using distributions fit to Federal Railroad Administration and U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration data on applicable accidents from 2000 to 2020. Uncertainty is propagated through the event sequence diagram to estimate the frequency and conditional probability of accident end states. The analysis identifies four scenarios with significant contributions to risk from hydrogen that are predicted to occur relatively frequently, which may inform priorities for reducing uncertainty. These scenarios are 1) overpressure events resulting from collisions with hydrogen release due to mechanical damage and delayed ignition, 2) jet fire events resulting from collisions with hydrogen release due to mechanical damage and immediate ignition, 3) jet fires resulting from fire or explosion initiating events involving the hydrogen tank and correct operation of the thermally-activated pressure relief device (TPRD) subsequent to the thermal insult, and 4) pressure burst resulting from fire or explosion initiating events involving the hydrogen tank and failure of the TPRD. Delayed and immediate hydrogen ignition probabilities are identified as being highly uncertain and potential candidates for reducing conservatism in the predicted frequencies for these two scenarios.

08 HYDROGEN↗

Evaluation of microcrack thermal shock damage in ceramics: Modeling and experiment

In this paper we present an experimental and theoretical study of the effect of microcrack damage on ceramic properties. For the experimental investigation, ceramic samples of aluminum oxide and reaction bonded silicon nitride (RBSN) are used. Thermal shock treatment from different temperatures up to 1000 C is applied to produce the microcracks. Both surface and bulk ultrasonic wave methods are used to correlate the change of elastic constants to microstructural degradation and to determine the change in elastic anisotropy induced by microcrack damage. For the theoretical investigation, damage mechanics, which relates microstructural damage to material service life and mechanical failure, is used. The change in elastic properties due to microcrack damage calculated from the theoretical model is compared with the experimental results for determination of the applicability of damage theory. It is shown that two independent experimental methods (bulk wave and surface wave) give the same results for shear moduli of damaged ceramics. The experimental results aagree reasonably well with the moduli predicted from the cracked solid model.

Chu, Y. C.↗

Fatigue damage growth mechanisms in continuous fiber reinforced titanium matrix composites

The role of fiber/matrix interface strength, residual thermal stresses, and fiber and matrix properties on fatigue damage accumulation in continuous fiber metal matrix composites (MMC) is discussed. Results from titanium matrix silicon carbide fiber composites is the primary topic of discussion. Results were obtained from both notched and unnotched specimens at room and elevated temperatures. The stress in the 0 deg fibers was identified as the controlling factor in fatigue life. Fatigue of the notched specimens indicated that cracks can grow in the matrix materials without breaking fibers.

Johnson, W. S.↗

Fatigue damage growth mechanisms in continuous fiber reinforced titanium matrix composites

The role of fiber/matrix interface strength, residual thermal stresses, and fiber and matrix properties on fatigue damage accumulation in continuous fiber metal matrix composites (MMC) will be discussed. Results from titanium matrix/silicon-carbide fiber composites will be the primary topic of discussion. Results have been obtained from both notched and unnotched specimens at room and elevated temperatures. The stress in the 0 deg fibers has been indentified as the controlling factor in fatigue life. Fatigue of the notched specimens indicated that cracks can grow many fiber spacings in the matrix materials without breaking fibers.

Johnson, W. S.↗

Damage Accumulations Predictions for Boiler Components Via Microstructurally Informed Material Models

The goal of the project was to model material behavior and degradation during cyclic plasticity— with and without hold time—for nickel-based superalloys used in USC (ultra-super-critical) and A-USC (advanced-ultra-super-critical) boiler components. The study provided physically informed models, capturing the microstructural changes taking place in the industrial components under cyclic loading and long duration stress (up to 300,000 hours) and high temperature exposure (1100°F/593°C to 1400°F/760°C). The major developments were: 1) Qualitative and quantitative understanding of microstructure evolution (gamma prime precipitates), deformation (dislocation density), and damage mechanisms of Haynes ® 282 alloy. 2) Qualitative understanding of microstructural features generating local strain variations. 3) A continuum damage mechanics model (CDM) for Haynes ® 282 alloy at 1100°F to 1400°F capturing cyclic behavior with and without hold time. 4) Structural analysis for creep and LCF life predictions of an USC thick-wall Grade 91 superheater steel header and understanding life sensitivity to wall thickness of an AUSC Haynes ® 282 header.

20 FOSSIL-FUELED POWER PLANTS↗

Neural Network Enhanced RKPM for Electrochemical-Mechanical Coupled Damage Modeling of Energy Storage Materials

Energy storage materials undergo significant charge cycling, which makes understanding their reliability and durability fundamental in predicting performance and service life. Strong electrochemical-mechanical coupling and highly anisotropic material properties contribute to the formation and propagation of micro-cracking, largely along material interfaces and grain boundaries. For Li-ion batteries, for example, lithium moving between electrodes during charging and discharging process causes expansion and contraction of grains, and the strongly anisotropic and nonlinearly [Li]-dependent grain material properties can cause grains to expand into and contract away from each other, leading to chemo-mechanical cracking. In the first part of this work, a RKPM based computational framework for solving the coupled solid-phase lithium conservation with Fickian diffusion and the lithium concentration dependent anisotropic mechanical problem subjected to a highly nonlinear Butler-Volmer boundary condition is introduced. The choice of RKPM completeness conditions for lithium concentration and mechanical deformation fields, and the variational consistency condition for the domain integration of the coupled problem is first determined. In the second part of this work, a neural network-enhanced reproducing kernel particle method (NN-RKPM) [1] is leveraged to accurately capture damage and crack propagation throughout the material, by learning the location, orientation, and sharpness of discontinuity while allowing for a coarser nodal distribution than that is necessary for capturing sharp solution transitions using traditional mesh-based methods. NN-RKPM is used to inform how crack opening and closure in turn affect the coupled chemical equations and material microstructure.

damage modeling↗

Benchmarking Mixed Mode Failure in Progressive Damage and Failure Analysis Methods

The verification and validation of progressive-damage-analysis finite element methods are difficult but critical tasks to undertake during their development. Verification exercises assess whether a predictive analysis tool produces results that are consistent with the fundamental concepts and assumptions of the tool under evaluation. Ideally, closed-form analytical solutions can be derived for which method verification results can be compared. Problems selected for computational tool verification are often simple and isolate individual features of the tool. In the case of progressive damage finite element methods, verifications should be performed to evaluate the ability of the model to predict the initiation of damage and its growth through the finite element mesh under a variety of conditions. Mabson et al. proposed a test case of a unidirectional, fiber-reinforced plate with a center crack subjected to tensile loads to evaluate matrix crack propagation predictions. The problem was modeled using the Abaqus Hashin continuum damage mechanics (CDM) model for fiber-reinforced composites. Different combinations of matrix strengths and element sizes were used in the simulations, and the results were compared to a closed-form solution based on linear elastic fracture mechanics (LEFM). It was determined that the Abaqus CDM model could predict the LEFM solution of Mode I cracks only when the finite element mesh density met specific requirements based on the material properties. This paper presents closed-form LEFM solutions for a center notch mixed mode (CNMM) verification problem. Parametric finite element analyses were developed using progressive damage analysis methods of both the Discrete Damage Mechanics (DDM) and CDM classes. The progressive damage analysis methods applied in the analyses of the CNMM problem include CompDam and the Floating Node Method. Analyses were conducted with various mode mixities and element sizes to verify that the damage models were working as intended and to identify any limits of applicability.

Leone, Frank↗

Acoustic Emission Analysis of Damage Progression in Thermal Barrier Coatings Under Thermal Cyclic Conditions

Damage evolution of electron beam-physical vapor deposited (EBVD-PVD) ZrO2-7 wt.% Y2O3 thermal barrier coatings (TBCs) under thermal cyclic conditions was monitored using an acoustic emission (AE) technique. The coatings were heated using a laser heat flux technique that yields a high reproducibility in thermal loading. Along with AE, real-time thermal conductivity measurements were also taken using infrared thermography. Tests were performed on samples with induced stress concentrations, as well as calcium-magnesium-alumino-silicate (CMAS) exposure, for comparison of damage mechanisms and AE response to the baseline (as-produced) coating. Analysis of acoustic waveforms was used to investigate damage development by comparing when events occurred, AE event frequency, energy content and location. The test results have shown that AE accumulation correlates well with thermal conductivity changes and that AE waveform analysis could be a valuable tool for monitoring coating degradation and provide insight on specific damage mechanisms.

calcium-magnesium-alumino-silicate (CMAS)↗

Damage detection in a laboratory-scale wellbore applying Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR NEWS)

We report Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR-NEWS) has been used to focus acoustic energy, and make measurements correlated with damage in a variety of industrial materials. Most studies using TR-NEWS have focused on relatively small objects and may have multiple acoustic sources. In Earth, within energy extraction and carbon sequestration settings, the structure and scale of wellbores makes acoustic focusing challenging, as has been demonstrated through numerical simulations. This paper explores the feasibility of applying TR NEWS for damage detection in wellbores by constructing a laboratory-scale wellbore, and using TR to focus and make dynamic linear and nonlinear elastic measurements on it. During successive cycles of localized mechanical damage induced in the sample, the hysteretic nonlinear elastic parameter α increased with progressive mechanical damage. In addition to these strain-dependent changes in α, the width and peak amplitude of the time reversal focused energy changed near the damage site.

58 GEOSCIENCES↗

Physics-based Multiscale Additively Manufactured Superalloy Design for Optimized High Cycle Fatigue Life (Final Report)

The objectives of this project are to: (i) Gain fundamental understandings towards the microscopic damage mechanisms, as impacted by pertinent materials properties (e.g. stacking fault energy (SFE) and microstructure (e.g., grain size), leading to high-cycle fatigue (HCF) damage to AM Ni-based superalloy parts; (ii) Provide scientific insight into the effect of testing frequency on damage mechanisms and fatigue life of AM Ni-based superalloy parts under HCF regime, thereby establishing an appropriate correlation between accelerated testing and materials’ true service life; (iii) Devise an accurate, experimentally validated multiscale model across atomic, micro- and meso-scales, to predict the cyclic stress-strain responses and fatigue damage accumulation for AM Ni-based superalloys under various loading frequencies.

36 MATERIALS SCIENCE↗

Microstructural Model for Creep-Fatigue Interaction in Grade 91 Steel

This report describes the completion of a crystal plasticity finite element simulation framework for creep-fatigue deformation and damage in Grade 91 steel. In addition to a description of the framework and a set of verification calculations, the report details an initial set of simulations applying the framework to examine low cycle fatigue and creep-fatigue interaction in Grade 91 at 600° C. Grade 91 is a likely material for future advanced microreactors and creep-fatigue will be a limiting structural damage mechanism, particularly for mobile reactors or load following systems. The framework described here could provide a better understanding of creep-fatigue damage mechanisms and directly examine creep, fatigue, and creep-fatigue interaction for Grade 91 at realistic component service conditions. This in turn could lead to improved design methods and component life estimation approaches, leading to more efficient and economical component designs.

36 MATERIALS SCIENCE↗

Numerical and experimental evaluation of mechanical performance of the multifunctional energy storage composites

This work presents numerical simulation methods to model the mechanical behavior of the multifunctional energy storage composites (MESCs), which consist of a stack of multiple thin battery layers reinforced with through-the-hole polymer rivets and embedded inside carbon fiber composite laminates. MESC has been demonstrated through earlier experiments on its exceptional behavior as a structural element as well as a battery. However, the inherent complex infrastructure of the MESC design has created significant challenges in simulation and modeling. A novel homogenization technique was adopted to characterize the multi-layer properties of battery material using physics-based constitutive equations combined with nonlinear deformation theories to handle the interface between the battery layers. Second, mechanical damage and failure modes among battery materials, polymer reinforcements, and carbon fiber-polymer interfaces were characterized through appropriate models and experiments. The model of MESCs has been implemented in a commercial finite element code in ABAQUS. A comparison of structural response and failure modes from numerical simulations and experimental tests are presented. The results of the study showed that the predictions of elastic and damage responses of MESCs at various loading conditions agreed well with the experimental data. © 2021

Materials Science↗

A Biaxial-Bending Test to Observe the Growth of Interacting Delaminations in a Composite Laminate Plate

It is not easy to isolate the damage mechanisms associated with low-velocity impact in composites using traditional experiments. In this work, a new experiment is presented with the goal of generating data representative of progressive damage processes caused by low-velocity impact in composite materials. Carbon fiber reinforced polymer test specimens were indented quasi-statically such that a biaxial-bending state of deformation was achieved. As a result, a three-dimensional damage process, involving delamination and delamination-migration, was observed and documented using ultrasonic and x-ray computed tomography. Results from two different layups are presented in this paper. Delaminations occurred at up to three different interfaces and interacted with one another via transverse matrix cracks. Although this damage pattern is much less complex than that of low-velocity impact on a plate, it is more complex than that of a standard delamination coupon test and provides a way to generate delamination, matrix cracking, and delamination-migration in a controlled manner. By limiting the damage process in the experiment to three delaminations, the same damage mechanisms seen during impact could be observed but in a simplified manner. This type of data is useful in stages of model development and validation when the model is capable of simulating simple tests, but not yet capable of simulating more complex and realistic damage scenarios.

McElroy, Mark↗

Investigation of performance deterioration of the CF6/JT9D, high-bypass ratio turbofan engines

The aircraft energy efficiency program within NASA is developing technology required to improve the fuel efficiency of commercial subsonic transport aricraft. One segment of this program includes engine diagnostics which is directed toward determining the sources and causes of performance deterioration in the Pratt and Whitney Aircraft JT9D and General Electric CF6 high-bypass ratio turbofan engines and developing technology for minimizing the performance losses. Results of engine performance deterioration investigations based on historical data, special engine tests, and specific tests to define the influence of flight loads and component clearances on performance are presented. The results of analysis of several damage mechanisms that contribute to performance deterioration such as blade tip rubs, airfoil surface roughness and erosion, and thermal distortion are also included. The significance of these damage mechanisms on component and overall engine performance is discussed.

Ziemianski, J. A.↗

Performance deterioration of commercial high-bypass ratio turbofan engines

The results of engine performance deterioration investigations based on historical data, special engine tests, and specific tests to define the influence of flight loads and component clearances on performance are presented. The results of analyses of several damage mechanisms that contribute to performance deterioration such as blade tip rubs, airfoil surface roughness and erosion, and thermal distortion are also included. The significance of these damage mechanisms on component and overall engine performance is discussed.

Mehalic, C. M.↗