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DOE OSTI2024

Double winding condensate CFT

We conjecture a two-dimensional conformal field theory built out of a linear dilaton and a compact β γ system deformed by winding condensates on each of the compact cycles. In particular, explicit expressions of the residues of the correlation functions are provided. As a worldsheet theory, it describes a stringy black hole in AdS 3 (supported by the Kalb-Ramond flux) at the Hawking-Page temperature. It is expected to be connected to the Horowitz-Polchinski-like solution near the Hagedorn temperature of thermal AdS 3 and Euclidean BTZ blackhole as we vary the temperature.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1993

Intrinsic fatigue crack growth rates for Al-Li-Cu-Mg alloys in vacuum

The influences of microstructure and deformation mode on inert environment intrinsic fatigue crack propagation were investigated for Al-Li-Cu-Mg alloys AA2090, AA8090, and X2095 compared to AA2024. The amount of coherent shearable delta-prime (Al3Li) precipitates and extent of localized planar slip deformation were reduced by composition (increased Cu/Li in X2095) and heat treatment (double aging of AA8090). Intrinsic growth rates, obtained at high constant K(max) to minimize crack closure and in vacuum to eliminate any environmental effect, were alloy dependent; da/dN varied up to tenfold based on applied Delta-K or Delta-K/E. When compared based on a crack tip cyclic strain or opening displacement parameter, growth rates were equivalent for all alloys except X2095-T8, which exhibited unique fatigue crack growth resistance. Tortuous fatigue crack profiles and large fracture surface facets were observed for each Al-Li alloy independent of the precipitates present, particularly delta-prime, and the localized slip deformation structure. Reduced fatigue crack propagation rates for X2095 in vacuum are not explained by either residual crack closure or slip reversibility arguments; the origin of apparent slip band facets in a homogeneous slip alloy is unclear.

Slavik, D. C.↗

NASA NTRSDate not supplied

Toughening of Boron Carbide Composites by Hierarchical Microstructuring

Due to a unique combination of properties including high hardness, low density, chemical and thermal stability, semi-conductivity, and high neutron absorption, boron carbide (B4C) is a potential candidate for various applications involving extreme environment. However, B4C’s current application is limited because of its low fracture toughness. In this study, a hierarchical microstructure design with features including TiB2 grains and graphite platelets was used to toughen B4C by simultaneously utilizing multiple toughening mechanisms including crack deflection, bridging, and micro-crack toughening. Using field-assisted sintering technology (FAST), B4C composites with dense and hierarchical microstructure were fabricated. Previously, the fracture toughness of fabricated B4C composites was measured at micro-scale using micro-indentation to have up to 56% improvement. In this work, the B4C composites’ fracture toughness was characterized at macro-scale using four-point bending methods and compared with previous results obtained at micro-scale. Micromechanics modeling of fracture behaviors for B4C-TiB2 composites was also performed to evaluate the contributions from experimentally observed toughening mechanisms. From four-point bending tests, B4C composites reinforced with both TiB2 grains (~15 vol%) and graphite platelets (~8.7 vol%) exhibited the highest fracture toughness enhancement from 2.38 to 3.65 MPa∙m^(1/2). The measured values were lower than those obtained using micro-indentation but maintained the general trends. The discrepancy between the indentation and four-point bending test results originated from the complex deformation behaviors triggered by the high contact load during indentation tests. Through micromechanics modeling, introduced thermal residual stress due to thermal expansion mismatch between B4C and TiB2, and weak interphases at B4C-TiB2 boundaries were identified as the main causes for experimentally observed toughness enhancement. These results proved the effectiveness of hierarchical microstructure designs for B4C toughening and can provide reference for the future design of B4C composites with optimized microstructures for further fracture toughness enhancement.

composites↗

DOE OSTI2022

Orientation-selected micro-pillar compression of additively manufactured 316L stainless steels: Comparison of as-manufactured, annealed, and proton-irradiated variants

In this work, irradiation response and deformation mechanisms of additively manufactured (AM) 316L stainless steel were studied by atomic scale characterization and micro-pillar compression. The AM 316L stainless steels were fabricated by direct energy deposition, a laser-based additive manufacturing process. Irradiation with 2 MeV protons at 360°C was performed to create ~1.8 displacements-per-atom (dpa) damage in AM 316L. Deformation behaviors of the as-manufactured, annealed, and proton-irradiated variants were studied, focusing on the effects of manufacturing-induced pores, residual stress, and irradiation-introduced defects (dislocation loops and voids). Micro-pillars were prepared from grains of pre-selected orientation, avoiding contributions of grain boundaries and allowing determination of resolved shear stress on {111} glide planes. Transmission electron microscopy was used to characterize the pre- and post-deformation microstructure. It was found that in the as-manufactured alloy variant, moving dislocations were the major deformation carrier, with noticeable blocking by fabrication-induced pores, In the annealed variant, hardness was reduced, and deformation was also accomplished by dislocation gliding. In the proton-irradiated variant, significant twinning was observed. Comparing measured resolved shear stress and predicted critical stress for dislocation dissociation, we conclude that irradiation hardening became high enough to activate twinning. Therefore, the deformation mechanism changes from dislocation gliding to twinning. The study is important for both processing optimization and performance evaluation of AM alloys for reactor applications.

36 MATERIALS SCIENCE↗

NASA NTRS1996

Optimum combining of residual carrier array signals in correlated noises

An array feed combining system for the recovery of signal-to-noise ratio (SNR) loss due to antenna reflector deformation has been implemented and is currently being evaluated on the Jet Propulsion Laboratory 34-m DSS-13 antenna. The current signal-combining system operates under the assumption that the white Gaussian noise processes in the received signals from different array elements are mutually uncorrelated. However, experimental data at DSS 13 indicate that these noise processes are indeed mutually correlated. The objective of this work is to develop a signal-combining system optimized to account for the mutual correlations between these noise processes. The set of optimum combining weight coefficients that maximizes the combined signal SNR in the correlated noises environment is determined. These optimum weights depend on unknown signal and noise covariance parameters. A maximum-likelihood approach is developed to estimate these unknown parameters to obtain estimates of the optimum weight coefficients based on residual carrier signal samples. The actual combined signal SNR using the estimated weight coefficients is derived and shown to converge to the maximum achievable SNR as the number of signal samples increases. These results are also verified by simulation. A numerical example shows a significant improvement in SNR performance can be obtained, especially when the amount of correlation increases.

Liang, R.↗

NASA NTRS1996

Optimum Combining of Residual Carrier Array Signals in Correlated Noises

Tan, H. H.↗

DOE OSTI2021

Large-Scale Welding Process Simulation by GPU Parallelized Computing

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions

Many materials of interest to Sandia transition from fluid to solid or have regions of both phases coexisting simultaneously. Currently there are, unfortunately, no material models that can accurately predict this material response. This is relevant to applications that "birth stress" related to geoscience, nuclear safety, manufacturing, energy production and bioscience. Accurately capturing solidification and residual stress enables fully predictive simulations of the evolving front shape or final product. Accurately resolving flow of proppants or blood could reduce environmental impact or lead to better treatments for heart attacks, thrombosis, or aneurism. We will address a science question in this proposal: When does residual stress develop during the critical transition from liquid to solid and how does it affect material deformation? Our hypothesis is that these early phases of stress development are critical to predictive simulation of material performance, net shape, and aging. In this project, we use advanced constitutive models with yield stress to represent both fluid and solid behavior simultaneously. The report provides an abbreviated description of the results from our LDRD "Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions," since we have written four papers that document the work in detail and which we reference. We give highlights of the work and describe the gravitationally driven flow visualization experiment on a model yield stress fluid, Carbopol, at various concentrations and flow rates. We were able to collapse the data on a single master curve by showing it was self-similar. We also describe the Carbopol rheology and the constitutive equations of interest including the Bingham-Carreau-Yasuda model, the Saramito model, and the HB-Saramito model including parameter estimation for the shear and oscillatory rheology. We present several computational models including the 3D moving mesh simulations of both the Saramito models and Bingham-Carreau-Yasuda (BCY) model. We also show results from the BCY model using a 3D level set method and two different ways of handling reduced order Hele-Shaw modeling for generalized Newtonian fluids. We present some first ever two-dimensional results for the modified Jeffries Kamani-Donley-Rogers constitutive equation developed during this project. We include some recent results with a successful Saramito-level set coupling that allows us to tackle problems with complex geometries like mold filling in a thin gap with an obstacle, without the need for remeshing or remapping. We report on some experiments for curing systems where fluorescent particles are used to track material flow. These experiments were carried out in an oven on Sylgard 184 as a model polymerizing system. We conclude the report with a summary of accomplishments and some thoughts on follow-on work.

36 MATERIALS SCIENCE↗

NASA NTRS1996

Studies of Radiation-Driven and Buoyancy-Driven Fluid Flows and Transport

It is well known that radiative heat transport influences many types of buoyant flows due to its effect on the temperature and thus density field in the fluid medium. It is of interest to study gaseous flows driven solely by radiation in the absence of buoyancy, particularly because of its application to astrophysical flows that are well known from astronomical observations and numerical simulation. However, no laboratory-scale experiments of this phenomenon have ever been conducted. To study the possibility of obtaining such flows in the laboratory, an apparatus was built to produce large temperature differences (Delta (T)) up to 300 K in a gas confined between flat parallel plates. SF6 was used as the radiatively-active gas because its Planck absorption length is much shorter than that of any other common non-reactive gas. The NASA-Lewis 2.2 second drop tower was used to obtain reduced gravity in order to suppress buoyancy effects. To image the resulting flows, a laser shearing interferometer was employed. Initial results indicate the presence of flow that does not appear to be attributable to the residual flow resulting from buoyancy influences before the drop. For Delta(T) greater than 70 K, slight deformations in the interferometer fringes seen at lower Delta(T) became large unsteady swirls. Such behavior did not occur for radiatively-inactive gases, suggesting that a flow driven solely by radiation was obtained in SF6 and to a lesser extent in CO2. This was more pronounced at higher pressures and plate spacings, consistent with our scaling predictions.

Ronney, Paul D.↗

NASA NTRS1994

Studies of Radiation-Driven and Buoyancy-Driven Fluid Flows and Transport

It is well known that radiative heat transport influences many types of buoyant flows due to its effect on the temperature and thus density field in the fluid medium. It is of interest to study gaseous flows driven solely by radiation in the absence of buoyancy, particularly because of its application to astrophysical flows that are well known from astronomical observations and numerical simulation. However, no laboratory-scale experiments of this phenomenon have ever been conducted. To study the possibility of obtaining such flows in the laboratory, an apparatus was built to produce large temperature differences (Delta T) up to 300 K in a gas confined between flat parallel plates. SF6 was used as the radiatively-active gas because its Planck absorption length is much shorter than that of any other common non-reactive gas. The NASA-Lewis 2.2 second drop tower was used to obtain reduced gravity in order to suppress buoyancy effects. To image the resulting flows, a laser shearing interferometer was employed. Initial results indicate the presence of flow that does not appear to be attributable to the residual flow resulting from buoyancy influences before the drop. For Delta T greater than 70 K, slight deformations in the interferometer fringes seen at lower Delta T became large unsteady swirls. Such behavior did not occur for radiatively-inactive gases, suggesting that a flow driven solely by radiation was obtained in SF6 and to a lesser extent in CO2 This was more pronounced at higher pressures and plate spacings, consistent with our scaling predictions.

Ronney, Paul D.↗

NASA NTRS2013

Laboratory Demonstration of Phase Induced Amplitude Apodization (PIAA) Coronagraph with Better than 10(exp -9) Contrast

We present coronagraphic images from the Phase Induced Amplitude Apodization (PIAA) coronagraph on NASA's High Contrast Imaging Testbed (HCIT) at the Jet Propulsion Lab, showing contrasts of 5x10(exp -1) averaged from 2-4 lambda/D, in monochromatic light at 808 nm. In parallel with the coronagraph and its deformable mirror and coronagraphic wavefront control, we also demonstrate a low-order wavefront control system, giving 100 x rms suppression of introduced tip/tilt disturbances down to residual levels of 10(exp -3) lambda/D. Current limitations, as well as broadband (10% fractional bandpass) preliminary results are discussed.

deformable mirror (DM)↗

DOE OSTI2023

Unraveling the Mechanics: Computational Modeling of Residual Stresses in U10Mo Fuel with Aluminum Cladding

LEU (Low Enriched Uranium) plate-type fuel elements consist of a high-density, low-enrichment U–Mo alloy-based fuel foil encapsulated in an aluminum cladding and is fabricated through the Hot Isostatic Pressing (HIP) technique. Understanding the mechanism of possible failure modes of nuclear fuel is critical to mitigate potential consequences. One of the major contributing factors in various failure modes is stress and it greatly affects the integrity under temperature, pressure, and irradiation. These stresses could originate from various sources, including manufacturing, and operation, and can lead to deformation, cracking, or even complete failure of fuel elements. This study focuses on the development of a computational model that accurately predicts the residual stresses generated in the U10Mo fuel during fabrication. It has been observed that cladding creep has a substantial impact on the residual stresses in the U10Mo fuel post the HIP fabrication process. Furthermore, during the HIP bonding process the fuel plate system is heated to a temperature of 560 oC and as a result, the aluminum cladding transitions from (Al 6061-T6 to -O). This presents a challenge in capturing the change in material properties accurately. Therefore, a temperature dependent creep model such as hyperbolic sine creep model is considered to estimate the creep properties of the Aluminum cladding. The proposed calibrated creep model accurately predicts the residual stresses in the U10Mo fuel foil and agrees well with the experiments.

42 ENGINEERING↗

DOE OSTI2021

Adjoint-Based Inversion of Geodetic Data for Sources of Deformation and Strain

An adjoint-based formulation leads to a particularly efficient approach for inverting geodetic measurements for the source of the deformation. Specifically, the quantities necessary to iteratively improve the fit to the observations can be computed with just three forward calculations, one to obtain the current residuals, another to solve the adjoint problem, and a third to compute the step length. An inversion algorithm utilizing the adjoint-based gradient is applied to a set of Interferometric Synthetic Aperture Radar (InSAR) data gathered between 2016 and 2018 over the Tulare Basin in California's Central Valley. Because the measured deformation is due to groundwater withdrawal, a penalty function is included in the inversion to avoid placing aquifer volume change in locations that are far from any documented wells. The solution of the inverse problem provides estimates of aquifer compaction that provide a match to the observed range changes while honoring the well data. The solution indicates an average aquifer volume loss of 2.17 km 3 /year over the two year period from January 2016 to January 2018, encompassing one drought year (2016) and one wet year (2017). Finally, this magnitude of lost volume is compatible with the 3.1 km 3 /year decrease in water volume for the entire Central Valley, estimated from GRACE satellite gravity data.

58 GEOSCIENCES↗

NASA NTRS1990

Method for detecting surface motions and mapping small terrestrial or planetary surface deformations with synthetic aperture radar

A technique based on synthetic aperture radar (SAR) interferometry is used to measure very small (1 cm or less) surface deformations with good resolution (10 m) over large areas (50 km). It can be used for accurate measurements of many geophysical phenomena, including swelling and buckling in fault zones, residual, vertical and lateral displacements from seismic events, and prevolcanic swelling. Two SAR images are made of a scene by two spaced antennas and a difference interferogram of the scene is made. After unwrapping phases of pixels of the difference interferogram, surface motion or deformation changes of the surface are observed. A second interferogram of the same scene is made from a different pair of images, at least one of which is made after some elapsed time. The second interferogram is then compared with the first interferogram to detect changes in line of sight position of pixels. By resolving line of sight observations into their vector components in other sets of interferograms along at least one other direction, lateral motions may be recovered in their entirety. Since in general, the SAR images are made from flight tracks that are separated, it is not possible to distinguish surface changes from the parallax caused by topography. However, a third image may be used to remove the topography and leave only the surface changes.

Gabriel, Andrew K.↗

NASA NTRS2012

Piezocomposite Actuator Arrays for Correcting and Controlling Wavefront Error in Reflectors

Three reflectors have been developed and tested to assess the performance of a distributed network of piezocomposite actuators for correcting thermal deformations and total wave-front error. The primary testbed article is an active composite reflector, composed of a spherically curved panel with a graphite face sheet and aluminum honeycomb core composite, and then augmented with a network of 90 distributed piezoelectric composite actuators. The piezoelectric actuator system may be used for correcting as-built residual shape errors, and for controlling low-order, thermally-induced quasi-static distortions of the panel. In this study, thermally-induced surface deformations of 1 to 5 microns were deliberately introduced onto the reflector, then measured using a speckle holography interferometer system. The reflector surface figure was subsequently corrected to a tolerance of 50 nm using the actuators embedded in the reflector's back face sheet. Two additional test articles were constructed: a borosilicate at window at 150 mm diameter with 18 actuators bonded to the back surface; and a direct metal laser sintered reflector with spherical curvature, 230 mm diameter, and 12 actuators bonded to the back surface. In the case of the glass reflector, absolute measurements were performed with an interferometer and the absolute surface was corrected. These test articles were evaluated to determine their absolute surface control capabilities, as well as to assess a multiphysics modeling effort developed under this program for the prediction of active reflector response. This paper will describe the design, construction, and testing of active reflector systems under thermal loads, and subsequent correction of surface shape via distributed peizeoelctric actuation.

piezoelectric actuation↗

NASA NTRS1992

Unsteady transonic Euler solutions using finite elements

A finite element solution of the unsteady Euler equations is presented and demonstrated for 2D airfoil configurations oscillating in transonic flows. Computations are performed by spatially discretizing the conservation equations using the Galerkin weighted residual method and then employing a multistage Runge-Kutta scheme to march forward in time. A mesh deformation scheme has been developed to efficiently move interior points in a smooth fashion as the airfoil undergoes rigid body pitch and plunge motion. Both steady and unsteady results are presented, and a comparison is made with solutions obtained using finite-volume techniques. The effects of using either a lumped or consistent mass matrix are presented; the finite element method provides an accurate solution for unsteady transonic flows about isolated airfoils.

Davis, Gary A.↗

NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗

NASA NTRS1991

The interpretation of crustal dynamics data in terms of plate motions and regional deformation near plate boundaries

During our participation in the NASA Crustal Dynamics Project under NASA contract NAS-27339 and grant NAG5-814 for the period 1982-1991, we published or submitted for publication 30 research papers and 52 abstracts of presentations at scientific meetings. In addition, five M.I.T. Ph.D. students (Eric Bergman, Steven Bratt, Dan Davis, Jeanne Sauber, Anne Sheehan) were supported wholly or in part by this project during their thesis research. Highlights of our research progress during this period include the following: application of geodetic data to determine rates of strain in the Mojave block and in central California and to clarify the relation of such strain to the San Andreas fault and Pacific-North American plate motions; application of geodetic data to infer post seismic deformation associated with large earthquakes in the Imperial Valley, Hebgen Lake, Argentina, and Chile; determination of the state of stress in oceanic lithosphere from a systematic study of the centroid depths and source mechanisms of oceanic intraplate earthquakes; development of models for the state of stress in young oceanic regions arising from the differential cooling of the lithosphere; determination of the depth extent and rupture characteristics of oceanic transform earthquakes; improved determination of earthquake slip vectors in the Gulf of California, an important data set for the estimation of Pacific-North American plate motions; development of models for the state of stress and mechanics of fold-and-thrust belts and accretionary wedges; development of procedures to invert geoid height, residual bathymetry, and differential body wave travel time residuals for lateral variations in the characteristic temperature and bulk composition of the oceanic upper mantle; and initial GPS measurements of crustal deformation associated with the Imperial-Cerro Prieto fault system in southern California and northern Mexico. Full descriptions of the research conducted on these topics may be found in the Semi-Annual status Reports submitted regularly to NASA over the course of this project and in the publications listed.

Solomon, Sean C.↗