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At least 163 records · Page 9

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NASA NTRS1998

Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet Molding Compound

Although polyimide based composites have been used for many years in a wide variety of elevated temperature applications, very little work has been done to examine the durability and damage behavior under more prototypical thermomechanical fatigue (TMF) loadings. Synergistic effects resulting from simultaneous temperature and load cycling can potentially lead to enhanced, if not unique, damage modes and contribute to a number of nonlinear deformation responses. The goal of this research was to examine the effects of a TMF loading spectrum, representative of a gas turbine engine compressor application, on a polyimide sheet molding compound (SMC). High performance SMCs present alternatives to prepreg forms with great potential for low cost component production through less labor intensive, more easily automated manufacturing. To examine the issues involved with TMF, a detailed experimental investigation was conducted to characterize the durability of a T650-35/PMR-15 SMC subjected to TMF mission cycle loadings. Fatigue damage progression was tracked through macroscopic deformation and elastic stiffness. Additional properties, such as the glass transition temperature (T(sub g) and dynamic mechanical properties were examined. The fiber distribution orientation was also characterized through a detailed quantitative image analysis. Damage tolerance was quantified on the basis of residual static tensile properties after a prescribed number of TMF missions. Detailed microstructural examinations were conducted using optical and scanning electron microscopy to characterize the local damage. The imposed baseline TMF missions had only a modest impact on inducing fatigue damage with no statistically significant degradation occurring in the measured macroscopic properties. Microstructural damage was, however, observed subsequent to 100 h of TMF cycling which consisted primarily of fiber debonding and transverse cracking local to predominantly transverse fiber bundles. The TMF loadings did introduce creep related effects (strain accumulation) which led to rupture in some of the more aggressive stress scenarios examined. In some cases this creep behavior occurred at temperatures in excess of 150 C below commonly cited values for T(sub g). Thermomechanical exploratory creep tests revealed that the SMC was subject to time dependent deformation at stress/temperature thresholds of 150 MPa/230 C and 170 MPa/180 C.

Castelli, Michael G.↗

NASA NTRS1988

Thermal-mechanical cyclic stress-strain responses of cast B-1900 + Hf

The fatigue response of B-1900 + Hf superalloy is investigated experimentally under combined thermal and mechanical strain cycling in air, and the results are compared with the existing thermomechanical data on B-1900 + Hf and with the results of a comprehensive study of the fatigue behavior of the alloy under isothermal conditions. It is found that the cyclic stress-strain behavior of the alloy under thermomechanical fatigue is different from the isothermal behavior, with more hardening observed both at high and low temperatures. It is concluded that the synergistic coupling between cyclic strains and temperature cannot be ignored in predicting the cyclic stress-strain behavior of the alloy under realistic conditions.

Marchand, N.↗

NASA NTRS1990

Plasticity analysis of fibrous composite laminates under thermomechanical loads

Elastic-plastic behavior of fibrous composite laminates is analyzed for coupled in-plane mechanical loads and uniform thermal changes. Constitutive equations of the individual fibrous layers are derived from a vanishing fiber diameter model that represents the essential axial constraint between the phases. This permits derivation of closed form equations for the overall yield condition, stress concentration factors, and instantaneous compliance. Thermoelastic properties of the phases and yield stress of the matrix phase are functions of temperature. The effect of the model assumptions on the predicted behavior of composite laminates is examined by comparing the calculated response under cyclic thermal changes to available theoretical results and experimental measurements.

Bahei-El-din, Yehia A.↗

DOE OSTI2020

A Dual Approach in Direct Ink Writing of Thermally Cured Shape Memory Rubber Toughened Epoxy

Bisphenol A-based epoxies are much used in a wide range of composite and coating applications due to their excellent thermomechanical properties. However, their 3D printability remains a challenge with most reported materials suffering from high brittleness and low toughness. In this work, we have described especially modified epoxy resins that enable 3D printing with both fast and slow curing rates. These materials exhibit greatly enhanced toughness, tunable thermomechanical properties, and excellent shape memory behavior. Two different printing systems, including a two-part static mixing printhead and a single extrusion printhead, were developed for fast- and slow-curing epoxies, respectively. The rheology of inks in both systems has been modified into printable thixotropic fluids with the aid of silica nanoparticles and other additives. Epoxide-functionalized telechelic polybutadiene was added into the resins, which are then introduced inside the epoxy network after cross-linking. The addition of polybutadiene rubber significantly improves the toughness (over 135%), fracture strain (over 200%), and shape memory behavior. By adding different amounts of the rubber telechelic, thermomechanical properties, including modulus, elongation, and Tg of epoxy, can be well controlled in a wide range to satisfy different applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1986

Toward improved durability in advanced combustors and turbines: Progress in the prediction of thermomechanical loads

NASA is sponsoring the Turbine Engine Hot Section Technology (HOST) Project to address the need for improved durability in advanced combustors and turbines. Analytical and experimental activities aimed at more accurate prediction of the aerothermal environment, the thermomechanical loads, the material behavior and structural responses to such loading, and life predictions for high temperature cyclic operation have been underway for several years and are showing promising results. Progress is reported in the development of advanced instrumentation and in the improvement of combustor aerothermal and turbine heat transfer models that will lead to more accurate prediction of thermomechanical loads.

Sokolowski, Daniel E.↗

DOE OSTI2023

Temporally continuous thermofluidic–thermomechanical modeling framework for metal additive manufacturing

Additive manufacturing (AM) is known to generate large magnitudes of residual stresses (RS) within builds due to steep and localized thermal gradients. In the current state of commercial AM technology, manufacturers generally perform heat treatments in effort to reduce the generated RS and its detrimental effects on part distortion and in-service failure. Computational models that effectively simulate the deposition process can provide valuable insights to improve RS distributions. Accordingly, it is common to employ Computational fluid dynamics (CFD) models or finite element (FE) models. While CFD can predict geometric and thermal-fluid behavior, it cannot predict the structural response (e.g., stress–strain) behavior. On the other hand, an FE model can predict mechanical behavior, but it lacks the ability to predict geometric and fluid behavior. Thus, an effectively integrated thermofluidic–thermomechanical modeling framework that exploits the benefits of both techniques while avoiding their respective limitations can offer valuable predictive capability for AM processes. In contrast to previously published efforts, the work herein describes a one-way coupled CFD-FEA framework that abandons major simplifying assumptions, such as geometric steady-state conditions, the absence of material plasticity, and the lack of detailed RS evolution/accumulation during deposition, as well as insufficient validation of results. Here, the presented framework is demonstrated for a directed energy deposition (DED) process, and experiments are performed to validate the predicted geometry and RS profile. Both single- and double-layer stainless steel 316L builds are considered. Geometric data is acquired via 3D optical surface scans and X-ray micro-computed tomography, and residual stress is measured using neutron diffraction (ND). Comparisons between the simulations and measurements reveal that the described CFD-FEA framework is effective in capturing the coupled thermomechanical and thermofluidic behaviors of the DED process. The methodology presented is extensible to other metal AM processes, including power bed fusion and wire-feed-based AM.

42 ENGINEERING↗

DOE OSTI2026

Formulation and Performance Evaluation of Epoxy Sealant Systems for Double-Shell Tank Bottom Refurbishment

The performance of epoxy sealants used in the refurbishment of double-shell tank (DST) systems requires balancing processability, thermomechanical stability, and adhesion to cementitious substrates. This study incorporates Heloxy 8 as a reactive diluent into Westlake 862 epoxy to tailor workability and cured-state properties. Rheological time-sweep analysis demonstrates that increasing the diluent content significantly reduces complex viscosity and extends workability, thereby improving pumpability and flow for large-area applications. However, the targeted 2-hour processing window is not fully achieved. Differential scanning calorimetry (DSC) confirms that all formulations cure at room temperature to glass transition temperatures ( T g ) at least 20 °C above the maximum DST operating temperature (27 °C), thereby ensuring service in the glassy regime. Dynamic mechanical analysis (DMA) reveals formulation-dependent reductions in tan delta and increases in storage modulus, indicating increasingly elastic and mechanically stable networks with diluent incorporation. Pull-off adhesion testing shows that modified formulations (70–90% Westlake epoxy) exhibit significantly higher adhesion strengths than the unmodified system. Grout cohesive failure indicates that interfacial bonding exceeds substrate strength. Collectively, these results demonstrate that controlled reactive diluent incorporation enables optimization of processing behavior, interfacial adhesion, and thermomechanical performance, supporting the suitability of the modified epoxy systems as durable sealant layers for cementitious barrier applications in hazardous waste containment infrastructure.

Differential scanning calorimetry↗

NASA NTRS2000

Bithermal Low-Cycle Fatigue Evaluation of Automotive Exhaust System Alloy SS409

This investigation provides, for the first time, cyclic strainrange-controlled, thermomechanical fatigue results for the ferritic stainless steel alloy SS409. The alloy has seen extensive application for automotive exhaust system components. The data were generated to calibrate the Total Strain Version of the Strainrange Partitioning (TS-SRP) method for eventual application to the design and durability assessment of automotive exhaust systems. The thermomechanical cyclic lifetime and cyclic stress-strain constitutive behavior for alloy SS409 were measured using bithermal tests cycling between isothermal extremes of 400 and 800 C. Lives ranged up to 10,000 cycles to failure with hold-times of 0.33 to 2.0 minutes. The bithermal fatigue behavior is compared to isothermal, strain-controlled fatigue behavior at both 400 and 800 C. Thermomechanical cycling was found to have a profound detrimental influence on the fatigue failure resistance of SS409 compared to isothermal cycling. Supplementary bithermal cyclic stress-strain constitutive tests with hold-times ranging from 40 seconds up to 1.5 hours were conducted to calibrate the TS-SRP equation for extrapolation to longer lifetime predictions. Observed thermomechanical (bithermal) fatigue lives correlated well with lives calculated using the calibrated TS-SRP equations: 70% of the bithermal fatigue data fall within a factor of 1.2 of calculated life; 85% within a factor of 1.4; and 100% within a factor of 1.8.

Lu, Gui-Ying↗

DOE OSTI2021

Metallic Fuel Performance Code Requirements for the Versatile Test Reactor Project

Metallic nuclear fuels have been proposed for use in several emerging nuclear reactor designs, and a number of codes have been developed to model these fuels and assess their performance. Qualification of these metallic nuclear fuels will ultimately require monitored irradiation of lead test assemblies, but the use of fuel performance codes can reduce the uncertainty associated with these efforts by quantifying uncertainties and estimating margins to failure ahead of time. In this work, metallic fuel performance code requirements are defined for the Versatile Test Reactor (VTR) project using input from the Experimental Breeder Reactor II functional requirements, operational requirements, and design criteria. This work focuses on the thermomechanical responses and irradiation behaviors of metallic fuel elements that are representative of the proposed VTR driver fuel design concepts. As such, many of the code requirements and physics/modeling discussions in this work are expected to be broadly applicable to metallic fuel applications outside of the VTR project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1982

HOST high temperature crack propagation

Methods for characterizing and predicting crack growth at elevated temperatures are discussed. Nonlinear behavior, thermal gradients, and thermomechanical cycling are discussed.

Orange, T. W.↗

NASA NTRS1986

Toward improved durability in advanced combustors and turbines - Progress in prediction of thermomechanical loads

Sokolowski, D. E.↗

NASA NTRS1987

Aircraft engine hot section technology: An overview of the HOST Project

NASA sponsored the Turbine Engine Hot Section Technology (HOST) Project to address the need for improved durability in advanced aircraft engine combustors and turbines. Analytical and experimental activities aimed at more accurate prediction of the aerothermal environment, the thermomechanical loads, the material behavior and structural responses to loads, and life predictions for cyclic high-temperature operation were underway for the last 7 years. The project has involved representatives from six engineering disciplines who are spread across three work sectors (industry, academia, and NASA). The HOST Project not only initiated and sponsored 70 major activities, but was also the keystone in joining the multiple disciplines and work sectors to focus on critical research needs. A broad overview of the project is given along with initial indications of the project's impact.

Sokolowski, Daniel E.↗

NASA NTRS1990

Aircraft engine hot section technology: An overview of the HOST Project

NASA sponsored the Turbine Engine Hot Section (HOST) project to address the need for improved durability in advanced aircraft engine combustors and turbines. Analytical and experimental activities aimed at more accurate prediction of the aerothermal environment, the thermomechanical loads, the material behavior and structural responses to loads, and life predictions for cyclic high temperature operation were conducted from 1980 to 1987. The project involved representatives from six engineering disciplines who are spread across three work disciplines - industry, academia, and NASA. The HOST project not only initiated and sponsored 70 major activities, but also was the keystone in joining the multiple disciplines and work sectors to focus on critical research needs. A broad overview of the project is given along with initial indications of the project's impact.

Sokolowski, Daniel E.↗

DOE OSTI2020

Constitutive behavior and processing maps of a new wrought magnesium alloy ZE20 (Mg-2Zn-0.2Ce)

ZE20 (Mg-2Zn-0.2Ce) 2 is a new wrought magnesium alloy with improved extrudability and mechanical properties [1]. To understand the constitutive behavior and workability of this new alloy, Gleeble thermomechanical testing has been carried out in this study. The flow stress behavior of ZE20 was investigated between 250 °C–450 °C and 10 –3 s –1 –1.0 s –1 in isothermal compression. Constitutive descriptions of the flow stress are provided. A new general approach at application of the extended Ludwik equation is demonstrated and was found to be more accurate than the hyperbolic sine Arrhenius model while having a similar number of model constants. Processing maps were developed based on the experimental results and are verified with microstructural investigation. A region of safe processing with non-basal texture and high activity of dynamic recrystallization (DRX) was found between 375 °C and 450 °C, from 10 –1 s –1 to 10–2.5 s –1 . A region of potentially safe processing with annealing that is associated with shear band nucleation of non-basal grains was identified for temperatures as low as 300 °C and rates as high as 10 –1 s –1 .

36 MATERIALS SCIENCE↗

NASA NTRS1985

Viscoplastic constitutive relationships with dependence on thermomechanical history

Experimental evidence of thermomechanical history dependence in the cyclic hardening behavior of some common high-temperature structural alloys is presented with special emphasis on dynamic metallurgical changes. The inadequacy of formulating nonisothermal constitutive equations solely on the basis of isothermal testing is discussed. A representation of thermoviscoplasticity is proposed that qualitatively accounts for the observed hereditary behavior. This is achieved by formulating the scalar evolutionary equation in an established viscoplasticity theory to reflect thermomechanical path dependence. To assess the importance of accounting for thermomechanical history dependence in practical structural analyses, two qualitative models are specified: (1) formulated as if based entirely on isothermal information; (2) to reflect thermomechanical path dependence using the proposed thermoviscoplastic representation. Predictions of the two models are compared and the impact the calculated differences in deformation behavior may have on subsequent lifetime predictions is discussed.

Robinson, D. N.↗

DOE OSTI2023

Organocatalysis in ring opening copolymerization as a means of tailoring molecular weight dispersity and the subsequent impact on physical properties in 4D printable photopolymers

Vat photopolymerization 3D printing has traditionally relied on free radical crosslinking between alkenes to produce non-degradable parts, which may have limited use in the biomedical and clinical spaces. Photopolymer resins containing functionalized degradable polymers, specifically polyesters, are greatly interesting for 3D printing tissue scaffolds and medical devices. Unfortunately, most polyesters produced for these applications have been made using metal-containing catalysts, which are not without risk for medical applications. Organocatalysis is a viable alternative route to achieving the same types of polyesters. Here, ring opening copolymerization (ROCOP) of allyl and cyclohexene-containing polyesters is examined using bipyridine and a guanidine-containing catalyst. The role of the catalysts, initiators, and cocatalysts are examined for bulk, open air ROCOP reactions. Unlike previous efforts with organocatalysis, the examined catalysts here could be used to tailor the dispersity of the polyesters, with ~10 kDa polyesters with dispersity ranging from 1.3 to 2.5 examined for the impact on rheological and thermomechanical properties related to resin/part behavior. The bipyridine catalysts and a thiourea cocatalyst further are shown, through the introduction of new fluorescence emissions of the purified polyesters. As a result, this work demonstrates that tuning the dispersity of polyester photopolymers provides a direct method of tailoring physical and optical properties in 3D/4D printable materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

pvcracks

SAND2024-00922O This software uses electroluminescence images to predict power loss due to cell cracks in photovoltaic modules. The software will incorporate trained variational autoencoder(s) to parameterize cell cracks detected in electroluminescence images of photovoltaic modules and relate cracks to electrical properties; reduced-order models of finite element simulations of electrical behavior of photovoltaic modules under thermomechanical stresses; reduced-order models of stress distributions; inside photovoltaic modules resulting from x-ray topography experiments; and image segmentation and splining methods to analyze x-ray topography measurements of cracked photovoltaic cells. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Hartley, James↗

NASA NTRS1988

Light-weight, high-performance metal matrix composites

Recent years have seen the development of a wide range of light-weight, high-performance aluminum powder metallurgy composites that combine both standard (6061 and 2124) and specialty matrix compositions (Al-Mg-Cu-Li and Al-Fe-Ce) with a wide variety of discontinuous reinforcements (Al2O3, B4C, and SiC). This paper reviews the fabrication and damage tolerance performance of these light-weight, high-performance composites. Particular attention is given to developing a general framework for understanding the interrelationship existing between microstructure, thermomechanical processing and ductility/fracture toughness behavior in these composite systems.

Rack, H. J.↗