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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
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Slow Strain Rate Tensile Testing to Assess the Ability of Superalloys to Resist Environment-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720, ATI 718Plus alloy, Haynes 282, and Inconel 740. Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

Heat resistant alloys↗
NASA NTRSDate not supplied

Experimental Observations of Damage States in Unnotched and Notched 3D Orthogonal Woven Coupons Loaded in Tension

This paper describes a series of unnotched and notched tensile tests on two 3D orthogonal woven architectures loaded in the warp direction. Dogbone specimens were used for the unnotched tests, and open-hole specimens were used for the notched tests. For each architecture and test type, two specimens were loaded under monotonic displacement control to failure, and two specimens were incrementally loaded to failure in five steps. X-ray computed tomography (CT) was used to characterize the woven architecture and defects on each specimen prior to testing. Digital image correlation (DIC) images were obtained from both sides of the specimen throughout the loading and unloading. For the incremental tests, X-ray CT was used to document the damage progression after each load increment. The results for both architectures and test specimens followed a similar pattern where matrix cracks formed perpendicular to the load direction and were primarily located between the stacks of warp tows. Two-piece failure path always occurred perpendicular to the loading direction, along the through-thickness segments of the Z-tows. The combination of stress concentrations due to the specimen geometry, weave geometry, and cut tows created stress concentrations that appear to initiate failure.

Woven materials↗
DOE OSTI2023

Deformation Behavior of β Phase in a WE54 Magnesium Alloy

Second phases play a significant role in the development of high-performance magnesium alloys with rare earth elements. Here, in situ tensile tests combined with synchrotron radiation were carried out to investigate the deformation behavior of β phases in a WE (Mg–Y–Gd–Nd) alloy. By lattice strain analysis, it was found that micro load continuously transferred from the soft α-Mg matrix to the hard β phases during the whole plastic deformation, while this behavior was much more obvious at the beginning of deformation. Based on diffraction peak broadening, Williamson–Hall (W–H) plotting was used to study the microstrain of β phases. The results showed that the microstrain of β phases increased rapidly within 4% plastic strain and reached the maximum at plastic strain of ~6.5%. Since the β phases acted as hard phases, the microstrain was considered as a sign of the stress concentration near phase interfaces. It was also suggested that the effective release of local stress concentration at the β/α-Mg interface benefited the ductility of the WE alloy by the plastic deformation of β phases and phase interface sliding.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Stress reduction in an isotropic plate with a hole by applied induced strains

Recently there has been much interest in adaptive structures that can respond to a varying environment by changing their properties. Shape memory alloys and piezoelectric materials can be used as induced strain actuators to reduce stresses in the regions of stress concentration. The objective of the work was to find the maximum possible reduction in the stress concentration factor in an isotropic plate with a hole by applying induced strains in a small area near the hole. Induced strains were simulated by thermal expansion.

Sensharma, Pradeep K.↗
NASA NTRS1993

Transverse Strength of SCS-6 Silicon Carbide Fibers

A diametral compression test was used to measure the transverse strength of SCS-6 SiC fibers before and after heat treatment. Subjecting fibers to diametral compression successfully produced transverse tensile failure in the form of fiber cracking along the same diametral plane in which the compressive load was applied. An analysis of the hoop stress along the diametral plane, in which the effects of the C core were included, showed that there is a large tensile hoop stress concentration in the SiC sheath at the interface between the C core and the SiC sheath, where the stress is 6.3 times greater than the stress present in a solid SiC fiber under identical loading. This high tensile hoop stress concentration promotes crack initiation near the core and significantly limits the capability of these fibers to withstand transverse compressive loading. The maximum tensile hoop stresses, located at the interface between the C core and SiC sheath, at the measured failure loads were 850 MPa for the as-received SCS-6 fiber and 1210 MPa for fibers exposed to a 1-h heat treatment at 1850°C in 138 MPa of Ar.

Jeffrey I. Eldridge↗
DOE OSTI2020

Improving stability of ALD ZrN thin film coatings over U-Mo dispersion fuel

Atomic layer deposition (ALD) of ZrN is a candidate technology for coating U-Mo dispersion fuel as a diffusion barrier coating. During the early development stages of the coating the ZrN deposition showed to be mechanically unstable and ultimately resulted in spalling. Based on experimental outcomes it was found that instabillity can be eliminated through the introduction of a thin amorphous (a) Al 2 O 3 interlayer coating deposited in between the ~1-μm thick ZrN and the U-Mo. substrate. To elucidate these findings simulations were performed with density functional theory (DFT) to measure work of adhesions at different interfaces while finite element modeling (FEM) was performed to measure the residual stress distribution. DFT indicated that the ZrN coating deposited over (a)-Al 2 O 3 is ~2.5 times stronger when compared to direct deposition over U or UO 2 substrate. While calculations from FEM recognized; (1) large stress concentrations can originate from the irregularly distributed native surface oxides (UO 2 ) over U-Mo and (2) stress concentrations can be reduced if those surface UO 2 can be modified to a uniform layer (achieved after application of a 8 nm (a)-Al 2 O 3 interlayer). These results provided explanations and confirmed the role played by interlayer in eliminating the original mechanical instability of the ZrN.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites

With the growing demand for enhanced automotive fuel efficiency and environmental sustainability, there is a need for lightweighting automotive components through innovative design and manufacturing processes. Here, this study leverages a combination of numerical iterative design optimization and hybrid additive manufacturing–compression molding (AM-CM) technique for metal polymer composites to lightweight an automotive seatback. The AM-CM process enables robust mechanical interlocking between metals and composites, boasting high stiffness and strength with low overall density. Replacing metallic components with such metal polymer composites allows for comparable mechanical performance while significantly reducing the overall weight. First, the automotive seatback design space is reduced to critical load carrying regions using topology optimization and high stress concentration areas are identified using finite element analysis. Next, a lightweight metal polymer subcomponent is designed for a high stress concentration region. The full seatback frame with spatially heterogeneous material-specific design is then iteratively optimized to enable enhanced stiffness with minimal weight. Overall, the automotive seatback frame designed with location-specific metal, polymer, and metal polymer composite materials weighs 20% less than the metal-only design while exhibiting similar stiffness.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Improved Joint Design for Box-Stiffened Panels

Mass and strength analyses and system requirements identified titanium-box-stiffened-skin wall candidate for lightweight fuselage of pressurized vehicle. Photoelastic models of stiffener-to-skin joint used to identify quickly modifications to joint that lowers severity of stress concentration. Results with various photoelastic models cut from polyurethane sheet led to novel diffusion-bond joint with reduced stress concentration.

Davis, R. C.↗
DOE OSTI2020

Transformation-induced fracture toughening in CuAlBe shape memory alloys: A phase-field study

Stress-induced transformation ahead of a crack tip can relax the stress concentration and produce fracture toughness in shape memory alloys (SMAs). In this manuscript, we utilize a nonisothermal phase-field model (PFM) to study the martensitic transformation induced crack tip toughening in CuAlBe SMA. The force-displacement curve, transformation zone and high stress zone in single crystalline samples show high dependency on the grain orientation with respect to the crack alignment. Comparison between isothermal and non-isothermal simulations reveals that the transformation-induced self-heating decreases the toughening capability by increasing the critical transformation stress. Investigating the high stress zones in CuAlBe and the nontransforming CuAl alloy shows that the toughening is obtained by redistributing the stress concentration far from the crack tip, as the high stress zone follows the tip of the transformation zone. Increasing the acuity of the crack tip is found to generate more symmetric martensite wings on both side of the crack axis and a more localized high stress zone. The polycrystal specimen displays higher toughening due to the internal constraints related to the presence of various grains with difference orientations. Depending on the orientation of the grain inclosing the crack tip, the toughening can be lower or higher. Finally, coincidence of the crack tip with a triple junction is found to improve the toughening behavior.

42 ENGINEERING↗
NASA NTRS1980

Finite element stress analysis of a notched coupon specimen for in-plane shear behaviour of composites

The results of a linear elastic, plane stress finite element investigation of the stress distribution in a double V-notched coupon specimen are presented for an isotropic material (steel) and five graphite/polyimide laminates: (0), (90), (0/90)s, (plus or minus 45)s and (0/90/plus or minus 45)s. Stress contours, stress profiles, and stress concentration factors are presented for specimens loaded through rigid fixtures. It is shown that the finite element analysis predicts a region of essentially uniform pure shear in the central portion of the specimen for all laminates considered. Stress concentrations vary considerably with laminate configuration. The influences of elastic fixtures and thermal stresses on the stress distribution in (0) laminates are also investigated. The (0) laminate is predicted to exhibit maximum pure shear in the center of the test section for both rigid and elastic fixtures. It is concluded that the specimen is a practicable candidate for use as a composite shear specimen.

Herakovich, C. T.↗
DOE OSTI2021

Revealing the effect of local stresses on twin growth mechanisms in titanium using synchrotron X-ray diffraction

Deformation twinning has a significant impact on the evolution of microstructure and mechanical response in hexagonal close packed (hcp) metals. Understanding the physical mechanisms associated with twin nucleation and growth processes is important to enable the broad use of hcp metals. While both nucleation and growth are conditioned by the local stress state, few studies have quantified it in bulk deformed samples. In this study, we reveal the effects of local stresses on twin thickening using in-situ synchrotron experiments with differential aperture X-ray microscopy. High purity Ti is deformed under four-point bending to activate {1012} tensile twins. Further, 3D stress fields with a spatial resolution of 0.5μm are mapped in the vicinity of low and high macroscopic Schmid factor (MSF) twins growing inside a grain. Reconciling this experimental analysis with recent twin growth models reveals that the growth of low MSF twins is limited by the nucleation of twin growth defects in the high-purity Ti sample. While growth-inducing defect nucleation may occur in many places on the interface of the high resolved shear stress (RSS)/MSF twin, the nucleation rate of twinning disconnections for the low MSF twin is high only at the end of the twin near a stress concentration. Once nucleated, these defects easily propagate into lower RSS regions of the grain resulting in twin growth. This work highlights the importance of stress concentrations not only for twin (embryo) nucleation, but also to the growth process of twins, particularly in low MSF twins.

36 MATERIALS SCIENCE↗
DOE OSTI2025

An airfoil-based synthetic actuator disk model for wind turbine aerodynamic and structural analysis

Here, this study introduces an airfoil-based refinement technique to enhance the Actuator Disk Model (ADM) for improved wind turbine aerodynamic load prediction and structural simulation in conjunction with Large Eddy Simulations of the wind flow. While ADM offers higher computational efficiency than the more detailed but resource-intensive Actuator Line Model (ALM), it traditionally lacks the resolution needed to capture the localized blade forces accurately. To address this limitation, we introduce a refinement technique that uses airfoil-specific data and employs interpolation-based grid point refinement, achieving ALM-comparable accuracy while preserving ADM's efficiency. Unlike conventional ADM that provides only rotor-disk averaged forces, our synthetic method tracks transient aerodynamic load variations over multiple blade revolutions, allowing us to calculate the distributions of maximum and minimum loads during typical cycles. Applied to the NREL 5 MW reference turbine, our enhanced ADM accurately predicts key aerodynamic parameters (angle of attack, axial velocity, lift, drag, axial and tangential forces along the blades) as well as structural responses (blade tip deflection, maximum stress, and stress concentration). Our results show that the tip deflection ranges from 2.33m (3.69 % of blade length) to 4.28m (6.79 %), with maximum stress concentration occurring near the blade root. This research demonstrates that a refined synthetic ADM approach can serve as a computationally efficient alternative for both aerodynamic analysis and structural simulation of wind turbine blades subjected to realistic wind fields.

17 WIND ENERGY↗
DOE OSTI2021

In Situ Synchrotron Tensile Investigations on Ultrasonic Additive Manufactured (UAM) Zirconium

The microstructure evolution of ultrasonic additive manufactured (UAM) zirconium under room temperature uniaxial tensile straining is reported. Miniature dog-bone tensile specimens of two orientations were cut from a UAM zirconium bar for in situ synchrotron tensile tests. Wide-angle X-ray scattering (WAXS) scanning at the Advanced Photon Source (APS) at Argonne National Laboratory was used to unveil the changes in microstructure of the entire gauge regions throughout the straining. A series of WAXS data analysis methods were utilized to quantify both elastic and plastic deformation mechanisms within the strained specimens. Stress concentrations were identified during early stage of plastic deformation, which become candidate necking positions and eventually lead to failure. Fracture surface analysis implied that these stress concentration locations may be correlated to the fabrication defects, providing insightful guidance for future improvement of the UAM zirconium process.

36 MATERIALS SCIENCE↗
DOE OSTI2022

In situ synchrotron tensile investigations on ultrasonic additive manufactured (UAM) zirconium

The microstructure evolution during room temperature uniaxial tensile straining of ultrasonic additive manufactured (UAM) zirconium was evaluated using the Advanced Photon Source (APS) facility. Miniature dog-bone tensile specimens of two orientations were cut from a UAM-fabricated zirconium bar for in situ synchrotron tensile tests. Wide-angle X-ray scattering (WAXS) scanning was used to unveil the changes in microstructure of the entire gauge regions throughout the straining. A series of WAXS data analysis methods were utilized to quantify both elastic and plastic deformation mechanisms within the strained specimens. Stress concentrations were identified during early stages of plastic deformation, which become candidate necking positions and eventually lead to failure. Additionally, fracture surface analysis implied that these stress concentration locations may be correlated to the fabrication defects, providing insightful guidance for future improvements of the UAM zirconium fabrication process.

36 MATERIALS SCIENCE↗
NASA NTRS1985

Joint design for improved fatigue life of diffusion-bonded box-stiffened panels

Simple photoelastic models were used to identify a cross-section geometry that would eliminate the severe stress concentrations at the bond line between box stiffeners diffusion bonded to a panel skin. Experimental fatigue-test data from titanium test specimens quantified the allowable stress in terms of cycle life for various joint geometries. It is shown that the effect of stress concentration is reduced and an acceptable fatigue life is achieved.

Davis, R. C.↗
DOE OSTI2020

Shoulder fillet effects in strength distributions of microelectromechanical system components

The failure forces and fracture strengths of polysilicon microelectromechanical system (MEMS) components in the form of stepped tensile bars with shoulder fillets were measured using a sequential failure chain methodology. Approximately 150 specimens for each of four fillet geometries with different stress concentration factors were tested. The resulting failure force and strength distributions of the four geometries were related by a common sidewall flaw population existing within different effective stressed lengths. The failure forces, strengths, and flaw population were well described by a weakest-link based analytical framework. Finite element analysis was used to verify body-force based expressions for the stress concentration factors and to provide insight into the variation of specimen effective length with fillet geometry. Monte Carlo simulations of flaw size and location, based on the strength measurements, were also used to provide insight into fillet shape and size effects. The successful description of the shoulder fillet specimen strengths provides further empirical support for application of the strength and flaw framework in MEMS fabrication and design optimization.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Stress analysis of advanced attack helicopter composite main rotor blade root end lug

Stress analysis of the Advanced Attack Helicopter (AAH) composite main rotor blade root end lug is described. The stress concentration factor determined from a finite element analysis is compared to an empirical value used in the lug design. The analysis and test data indicate that the stress concentration is primarily a function of configuration and independent of the range of material properties typical of Kevlar-49/epoxy and glass epoxy.

Baker, D. J.↗
NASA NTRS2012

Investigation of Effects of Material Architecture on the Elastic Response of a Woven Ceramic Matrix Composite

To develop methods for quantifying the effects of the microstructural variations of woven ceramic matrix composites on the effective properties and response of the material, a research program has been undertaken which is described in this paper. In order to characterize and quantify the variations in the microstructure of a five harness satin weave, CVI SiC/SiC, composite material, specimens were serially sectioned and polished to capture images that detailed the fiber tows, matrix, and porosity. Open source quantitative image analysis tools were then used to isolate the constituents and collect relevant statistics such as within ply tow spacing. This information was then used to build two dimensional finite element models that approximated the observed section geometry. With the aid of geometrical models generated by the microstructural characterization process, finite element models were generated and analyses were performed to quantify the effects of the microstructure and its variation on the effective stiffness and areas of stress concentration of the material. The results indicated that the geometry and distribution of the porosity appear to have significant effects on the through-thickness modulus. Similarly, stress concentrations on the outer surface of the composite appear to correlate to regions where the transverse tows are separated by a critical amount.

Goldberg, Robert K.↗