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NASA NTRS1977

The effect of outgassing upon the closure of cracks and the strength of lunar analogues

The effect of an ultrahigh vacuum and low water vapor pressure on the stress-strain relation in rocks was studied in order to understand geologic and tectonic processes of the moon. Terrestrial basaltic rocks carefully outgassed in high vacuum provided the sample material for the compression tests reported here. The tests were conducted either under 1 atm air saturated with moisture, or under high vacuum. Results of the stress-strain determinations indicated that the dry rocks could show as much as twice the strength of the wet rocks. The data may also provide a means of reconciling the high strength and high temperature exhibited by the lunar interior.

Mizutani, H.↗

DOE OSTI2025

Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers

High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fraction (65 % volume fraction) are used for the study. The mechanical properties (tensile strength and modulus), magnetic properties (maximum energy density, coercivity, remanence) are reported. Manufacturing parameters such as layer height, barrel temperatures, screw speed and gantry feed rate are optimized to obtain the highest possible density of the magnets using a small-scale desktop material extrusion printer. Large scale integrated additive manufacturing-compression molding (AM-CM) is then utilized to increase the density of the magnets by reducing porosity defects common in the material extrusion process. The density of as-printed magnets was 5.2 g/cm 3 with a BH max value of 124.14 kJ/m 3 , tensile strength of 20 MPa and a modulus of 2 GPa. AM-CM increased the density of the compound by 5.5 % (5.49 g/cm 3 ). The reduction in porosity was confirmed using X-ray tomography (XCT). Improvement in mechanical strength of the material was also observed, with an increase in tensile strength of 25 % (25.09 MPa) and increase in tensile modulus of 275 % (5.49 GPa). Scanning electron microscopy showed increased particle-matrix adhesion with the integrated AM-CM process.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Ceramic composites: A review of toughening mechanisms and demonstration of micropillar compression for interface property extraction

We present that ceramic fiber–matrix composites (CFMCs) are exciting materials for engineering applications in extreme environments. By integrating ceramic fibers within a ceramic matrix, CFMCs allow an intrinsically brittle material to exhibit sufficient structural toughness for use in gas turbines and nuclear reactors. Chemical stability under high temperature and irradiation coupled with high specific strength make these materials unique and increasingly popular in extreme settings. This paper first offers a review of the importance and growing body of research on fiber–matrix interfaces as they relate to composite toughening mechanisms. Second, micropillar compression is explored experimentally as a high-fidelity method for extracting interface properties compared with traditional fiber push-out testing. Three significant interface properties that govern composite toughening were extracted. For a 50-nm-pyrolytic carbon interface, the following were observed: a fracture energy release rate of ~2.5 J/m 2 , an internal friction coefficient of 0.25 ± 0.04, and a debond shear strength of 266 ± 24 MPa. Lastly, this research supports micromechanical evaluations as a unique bridge between theoretical physics models for microcrack propagation and empirically driven finite element models for bulk CFMCs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1985

Glass breaking strength: The role of surface flaws and treatments

Although the intrinsic strength of silicon dioxide glass is of the order of 10 to the 6th power lb/sq in, the practical strength is roughly two orders of magnitude below this theoretical limit, and depends almost entirely on the surface condition of the glass, that is, the number and size of flaws and the residual surface compression (temper) in the glass. Glass parts always fail in tension when these flaws grow under sustained loading to some critical size. Research associated with glass encapsulated crystalline-Si photovoltaic (PV) modules has greatly expanded our knowledge of glass breaking strength and developed sizeable data base for commercially available glass types. A detailed design algorithm is developed for thickness sizing of rectangular glass plates subject to pressure loads. Additional studies examine the strength of glass under impact loading conditions such as that caused by hail. Although the fundamentals of glass breakage are directly applicable to thin film modules, the fracture strength of typical numerical glass must be replaced with data that reflect the high temperature tin oxide processing, laser scribing, and edge processing peculiar to thin film modules. The fundamentals of glass breakage applicable to thin film modules and preliminary fracture strength data for a variety of 1 ft square glass specimens representing preprocessed and post processed sheets from current amorphous-Si module manufacturers are presented.

Moore, D.↗

DOE OSTI2025

Further Development of the Tamped Richtmyer-Meshkov Instability Method and Application to Molybdenum Dynamic Strength Calibration and Tabulation

The high pressure and high strain rate dynamic strength of Mo is experimentally and computationally investigated in the 3–20 GPa stress, 50–600 C temperature, and 10 5 –10 6 /s strain rate regimes using a modified tamped Richtmyer-Meshkov instability (RMI) method. Modifications to the tamped RMI method include a method to determine loading states during strain, a new strength calibration function based on interface shape, and a robust uncertainty quantification method. These modifications improve fidelity of the tamped RMI method, allowing evaluation of the compensating effects of pressure hardening, strain rate hardening, strain hardening, and thermal softening. The new calibration function based on interface shape is not limited to sinusoidal corrugations and could be applied to additional interface shapes. Plate impact experiments are performed at Argonne National Laboratory’s Advanced Photon Source’s Dynamic Compression Sector operated by Washington State University (DCS), driving a planar shock front through a corrugated Mo-D 2 O or Mo-C 8 F 18 interface, forcing the corrugation to significantly deform. The extent of interfacial deformation, RMI growth, is experimentally observed using X-ray phase contrast imaging at the DCS. RMI jet lengths and jet shapes are extracted from the experimental radiographs, then used to calibrate numerical simulations performed with the Sandia National Laboratories (SNL) hydrocode CTH. Mo yield strength, Y, as a function of shock pressure, P, strain rate, $\dot{\varepsilon }$, accumulated strain, ϵ, relative volumetric compression, RD , and temperature, T , is determined for each impact experiment and presented. The calibrated Mo yield strength values range 1.2–1.8 GPa, with strength generally decreasing as the impact stress increases. This trend is likely caused by thermal softening or strain localization. The tabular yield strength versus loading condition data presented in this paper can be used to fit complex strength models.

Voorhees, T. J. [Sandia National Lab. (SNL-CA), Li↗

DOE OSTI2022

Quasi-isentropic compression of an additively manufactured aluminum alloy to 14.8 GPa

We uniaxially and shocklessly compressed an additively manufactured aluminum alloy, laser powder bed fusion (LPBF) AlSi10Mg, to peak stresses ranging from 4.4 to 14.8 GPa at peak strain rates on the order of [Formula: see text] via a series of magnetic loading experiments to measure the principal isentrope, yield strength, and shear modulus as a function of material orientation and applied stress. We did not observe significant anisotropy in any of the measured quantities. We found that the principal isentrope, within the uncertainty and up to our peak stress, overlaps the material’s Hugoniot. We measured yield strengths and shear moduli ranging from 0.28 to 0.81 GPa and 36 to 52 GPa, respectively. Our results indicate that LPBF AlSi10Mg behaves similarly to wrought Al alloys under quasi-isentropic compression.

Brown, Nathan P.↗

DOE OSTI2019

Production of Hydrogel Microneedles from Fish Scale Biopolymer

This work presents for the first time, a scalable, low cost method for producing hydrogel microneedles from fish scales derived biopolymer using a modified low temperature press method. The microneedles are made from cross-linked hydrolyzed collagen (HC). The suitability of the microneedles for drug loading were tested by loading with Ferrous gluconate. Force analysis carried out in compression mode showed that the microneedles could withstand up to 0.136 N per microneedle before fracture which is sufficient strength to pierce the skin. The cross-linked microneedles swelled to 340% of their original mass in PBS and within 24 h released 34.5% of the loaded drug, while the non cross-linked microneedles dissolved within minutes. Chemical testing of the released drug confirmed that the drug released retained its chemical structure by forming colored complex with acetylsalicylic acid and UV spectrometry was used to quantify the concentration released. FTIR analysis confirmed the modified structure of the polymer when cross-linked. This proposed method allows cross-linking at room temperature using a thermal press method which can be easily scaled up.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Development of Ti 3 SiC 2 MAX phase tubular structures for solar receiver applications

Solar receiver tubes are key components of concentrating solar-thermal power (CSP) systems that harvest solar energy. For better efficiency, the Gen3 CSP receivers, which collect heat into a heat transfer fluid, require a temperature exceeding 700 °C during operation and need to perform under extreme conditions of high temperature and high thermal stress. Operators are seeking CSP designs using new high-temperature structural materials with high thermal conductivity and high creep resistance to achieve a design life of 30 years and thus help recover the plant capital cost sooner. MAX phase materials, which consist of an early transition metal element, an A-group element, and carbon or nitrogen, are expected to exhibit high creep resistance as well as high fracture toughness. Here, in this paper, we describe fabricating both (1) dense Ti 3 SiC 2 MAX phase disks and (2) short-length tubes using field-assisted sintering technology (FAST). First, the disk samples that we fabricated are fully dense and contain ≈90 % Ti 3 SiC 2 MAX phase materials and ≈10 % TiC phase materials. We determined a flexure strength of 519 ± 32 MPa by conducting a four-point bending test at room temperature with rectangular bar samples of ≈100 % density. The thermal conductivity of the Ti 3 SiC 2 MAX phase samples, measured by light flashing analysis, decreases linearly from a value of 41 W . m -1 . K -1 at room temperature to a value of 36 W . m -1 . K -1 at 650 °C. A solar reflectance measurement of the Ti 3 SiC 2 MAX phase revealed that, temperature increases from 400 to 1400 °C, thermal emittance increases from 0.39 to 0.49, while selectivity decreases from 1.8 to 1.4, respectively. Whereas the surface oxidized MAX phase samples after 100 h exposure to air at 1000 °C exhibit that of SiC. Next, we discuss fabrication of the crack-free Ti 3 SiC 2 MAX phase tubular structures accomplished by using FAST processing in graphite bedding. A Ti 3 SiC 2 MAX phase content of > 95 % with traceable ≈3% remaining TiC phase and ≈15 % porosity were demonstrated after high-temperature annealing. An average fracture strength of ≈250 MPa was determined with Ti 3 SiC 2 MAX phase tubes of ≈85 % density by diametral compression testing at room temperature. Our work demonstrated that using FAST processing to produce Ti 3 SiC 2 MAX phase tubular structures for CSP receiver applications is a viable approach.

14 SOLAR ENERGY↗

DOE OSTI2019

Experimental Studies of Anisotropy on Borehole Breakouts in Mancos Shale

Calculating the size and orientation of borehole breakouts is one of the key methods for determining the orientation and magnitudes of the in situ stresses in the subsurface. To better understand the effects of anisotropy on borehole breakouts, experiments were conducted on Mancos Shale, a finely laminated mudrock. A novel testing configuration was developed to conduct borehole breakout experiments in a standard triaxial vessel and load frame. Samples were prepared at three different orientations and deformed under 6.9 to 20.7 MPa confining pressure. The results show a variation of peak strength and breakout geometry depending on the lamination orientation. Samples deformed parallel to laminations failed at a higher maximum compressive stress than samples deformed perpendicular to laminations, which were stronger than inclined samples. These relationships are quantified by a cosine-based failure envelope. Observed breakout shapes in perpendicular samples are V-shaped and symmetric around the borehole, which advance as a series of fractures of increasing size into the sidewalls. In inclined samples, fractures form along weaker laminations planes and grow in an en echelon pattern towards the axial stress direction. In parallel samples, long fractures grow from the wellbore towards the axial stress direction. The observed geometries point to potential sources of error in calculating in situ stresses from borehole breakouts.

58 GEOSCIENCES↗

DOE OSTI2023

Investigation of Deformation Behavior of Additively Manufactured AISI 316L Stainless Steel with In Situ Micro-Compression Testing

Additive manufacturing techniques are being used more and more to perform the precise fabrication of engineering components with complex geometries. The heterogeneity of additively manufactured microstructures deteriorates the mechanical integrity of products. In this paper, we printed AISI 316L stainless steel using the additive manufacturing technique of laser metal deposition. Both single-phase and dual-phase substructures were formed in the grain interiors. Electron backscatter diffraction and energy-dispersive X-ray spectroscopy indicate that Si, Mo, S, Cr were enriched, while Fe was depleted along the substructure boundaries. In situ micro-compression testing was performed at room temperature along the [001] orientation. The dual-phase substructures exhibited lower yield strength and higher Young’s modulus compared with single-phase substructures. Our research provides a fundamental understanding of the relationship between the microstructure and mechanical properties of additively manufactured metallic materials. The results suggest that the uneven heat treatment in the printing process could have negative impacts on the mechanical properties due to elemental segregation.

36 MATERIALS SCIENCE↗

DOE OSTI2016

CONVECTIVE PROPERTIES OF ROTATING TWO-DIMENSIONAL CORE-COLLAPSE SUPERNOVA PROGENITORS

We explore the effects of rotation on convective carbon, oxygen, and silicon shell burning during the late stages of evolution in a 20 M {sub ⊙} star. Using the Modules for Experiments in Stellar Astrophysics we construct one-dimensional (1D) stellar models both with no rotation and with an initial rigid rotation of 50% of critical. At different points during the evolution, we map the 1D models into 2D and follow the multidimensional evolution using the FLASH compressible hydrodynamics code for many convective turnover times until a quasi-steady state is reached. We characterize the strength and scale of convective motions via decomposition of the momentum density into vector spherical harmonics. We find that rotation influences the total power in solenoidal modes, with a slightly larger impact for carbon and oxygen shell burning than for silicon shell burning. Including rotation in 1D stellar evolution models alters the structure of the star in a manner that has a significant impact on the character of multidimensional convection. Adding modest amounts of rotation to a stellar model that ignores rotation during the evolutionary stage, however, has little impact on the character of the resulting convection. Since the spatial scale and strength of convection present at the point of core collapse directly influence the supernova mechanism, our results suggest that rotation could play an important role in setting the stage for massive stellar explosions.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1982

A repair technology program at NASA on composite materials

Repair techniques for graphite/epoxy and graphite/polyimide composite structures are discussed. Tension and compression test results for several basic repair processes that were applied to damaged specimens are shown to approach the strength of undamaged specimens. Other repair configurations currently under investigation are illustrated, and plans in the repair technology program are presented.

Deaton, J. W.↗

NASA NTRS1983

SEASAT observations of lithospheric flexure seaward of trenches

Lithospheric flexure seaward of deep ocean trenches in SEASAT altimeter observations of the marine geoid. In fact, mechanical models of lithospheric flexure can be tested directly on the SEASAT altimeter data. A simple elastic model was used for the oceanic lithosphere and, after least squares adjustments, estimates of model parameters were recovered including Outer Rise (OR) amplitude, OR wavelength, and effective lithospheric thickness. Effective lithospheric thickness was recovered for five regions: the Mariana, the Kuril, the Philippine, the Aleutian and the Middle America OR. These results support the suggestion of Bodine et al. (1981) that effective thickness, T, increased with age of lithosphere in approximate accord with the relation T approximately equals x age to the 1/2 power where C approximately equals 4 km x my to the -1/2 power. Altimetric results agree more closely with this relation than do published results based on bathymetric data. The close agreement with the thickness-age relation suggests that there is no longer any need to assume that significant horizontal compression acts across the Kuril, Marianas and Izo-Bonin trenches. This thickness-age relation implies that flexural strength of the oceanic lithosphere is temperature controlled.

Mcadoo, D. C.↗

NASA NTRS1984

Seasat observations of lithospheric flexure seaward of trenches

Lithospheric flexure seaward of deep ocean trenches is evident in Seasat altimeter observations of the marine geoid. In fact, mechanical models of lithospheric flexure can be tested directly on the Seasat altimeter data. A simple elastic model has been used for the oceanic lithosphere and, after least squares adjustments, estimates have been recovered of model parameters including outer rise (OR) amplitude, OR wavelength, and effective lithospheric thickness. Effective lithospheric thicknesses have been recovered for six regions: the Mariana, the Kuril, the Philippine, the Aleutian, the Izu-Bonin, and the Middle America OR's. These results support the proposition that effective thickness Te increases with age of lithosphere in approximate accord with the relation Te approximately C x square root of age where C approximately 4 km/square root of (m.y.). In fact, altimetric results agree more closely with this relation than do published results based on bathymetric data. The close agreement with the thickness-age relation suggests that there is no longer any need to assume that significant horizontal compression acts across the Kuril, Marianas, and Izu-Bonin trenches. This thickness-age relation implies that flexural strength of the oceanic lithosphere is temperature controlled.

Mcadoo, D. C.↗

NASA NTRS1988

Structural efficiency study of graphite-epoxy aircraft rib structures

Attention is given to the structural efficiencies obtainable with optimally designed graphite/epoxy wing rib panel configurations that are potentially economically manufacturable. Some ribs are commonly used as fuel cell closeout panels, and are accordingly subjected to out-of-plane pressure loads in addition to the in-plane axial compressive and shear loads resulting from the wing loading. The present minimum-weight panel designs satisfy buckling and strength constraints for wing rib panels subjected to a wide range of combined load conditions.

Swanson, Gary D.↗

NASA NTRS1988

Magnetohydrodynamic bending waves in a current sheet

The physical properties of MHD bending waves in an isothermal, compressible, low-beta, three-dimensional current sheet of finite thickness in which the magnetic field direction and strength varies are considered. The case of the wavenumber (k) to circular frequency ratio being greater than the Alfven velocity outside the layer (V sub A) corresponds to one-sided surface waves, and it is suggested that the heliospheric current sheet ripples are not this type of bending wave. The case of k/omega of less than V sub A describes the interaction of freely and obliquely propagating MHD waves with the layer, while the case of k/omega = V sub A describes an Alfven wave propagating parallel to but having no interaction with the layer.

Musielak, Z. E.↗

NASA NTRS1990

Tensile stress acoustic constants of unidirectional graphite/epoxy composites

Previously, the stress acoustic constants (SACs) of unidirectional graphite/epoxy composites were measured to determine the nonlinear moduli of this material. These measurements were made under compressive loading in order to obtain the sufficient number of values needed to calculate these moduli. However, because their strength in tension along fiber directions can be several times greater, most composites are used under tensile loading. Thus, it is important to characterize the nonlinear properties of these materials in tension as well. The SACs which are defined as the slope of the normalized change in ultrasonic 'natural' velocity as a function of stress were measured in a unidirectional laminate of T300/5208 graphite/epoxy. Tensile load was applied along the fiber axis with the ultrasonic waves propagating perpendicular to the fiber direction. Changes in velocity were measured using a pulsed phase locked loop ultrasonic interferometer with the nominal frequency of the ultrasonic waves being 2.25 MHz.

Prosser, W. H.↗

NASA NTRS1990

Tensile Stress Acoustic Constants of Unidirectional Graphite/Epoxy Composites

Previously, the stress acoustic constants (SAC's) of unidirectional graphite/epoxy composites were measured to determine the nonlinear moduli of this material. These measurements were made under compressive loading in order to obtain the sufficient number of values needed to calculate these moduli. However, because their strength in tension along fiber directions can be several times greater, most composites are used under tensile loading. Thus, it is important to characterize the nonlinear properties of these materials in tension as well. The SAC's which are defined as the slope of the normalized change in ultrasonic "natural" velocity as a function of stress were measured in a unidirectional laminate of T300/5208 graphite/epoxy. Tensile load was applied along the fiber axis with the ultrasonic waves propagating perpendicular to the fiber direction. Changes in velocity were measured using a pulsed phase locked loop ultrasonic interferometer with the nominal frequency of the ultrasonic waves being 2.25 MHz.

Prosser, W. H.↗