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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Seshadri, Banavara R.↗
DOE OSTI2024

Quantification of grain boundary effects on the geometrically necessary dislocation density evolution and strain hardening of polycrystalline Mg 4Al using in situ tensile testing in scanning electron microscope and HR-EBSD

In situ tensile testing in a scanning electron microscope (SEM) in conjunction with high-resolution electron backscatter diffraction (HR-EBSD) under load was used to characterize the evolution of geometrically necessary dislocation (GND) densities at individual grain boundaries as a function of applied strain in a polycrystalline Mg—4Al alloy. The increase in GND density was investigated at plastic strains of 0 %, 0.6 %, 2.2 %, 3.3 % from the area including 76 grains and correlated with (i) geometric compatibility between slip systems across grain boundaries, and (ii) plastic incompatibility. We develop expressions for the grain boundary GND density evolution as a function of plastic strain and plastic incompatibility, from which uniaxial tensile stress-strain response of polycrystalline Mg—4Al are computed and compared with experimental measurement. The findings in this study contribute to understanding the mechanisms governing the strain hardening response of single-phase polycrystalline alloys and more reliable prediction of mechanical behaviors in diverse microstructures.

Geometrically necessary dislocations↗
DOE OSTI2026

Extended continuous cooling transformation diagram for 410 stainless steel encompassing δ → γ and γ → αʹ transformations determined by dilatometry

In this study, we use dilatometry to construct an extended Continuous Cooling Transformation (CCT) diagram for 410 stainless steel, capturing both δ → γ and γ → αʹ transformations specifically for directed energy deposition (DED) additive manufacturing (AM) applications. To ensure that the findings are representative of AM specific microstructures and compositions, dilatometry coupons were extracted from a wire arc DED wall, thereby preserving the inherent microstructural and compositional variability within the material. The on-heating phase transformations, including A c1 , A c3 , and γ → δ, were found to be essentially location independent, despite the typical heterogeneity associated with AM. Conversely, increasing cooling rates were observed to shift the start and finish temperatures of both δ → γ and γ → αʹ transformations to lower values. The resulting extended CCT diagram offers a more complete depiction of phase transformation behavior in the system, enabling accurate microstructure evolution modeling and residual stress predictions specifically for directed energy deposition additive manufacturing applications.

Additive manufacturing↗
NASA NTRS1989

Elastic crack bridging in ceramic and intermetallic matrix composites

A micromechanics analytical model based on the consistent shear lag theory is developed for predicting the failure modes in a fiber reinforced unidirectional ceramic and intermetallic matrix composite. The model accounts for the relatively large matrix stiffness. The fiber and matrix stresses are established as functions of the applied stress, crack geometry, and most importantly, the microstructural properties of the constituents. From the predicted stress, the mode of failure is established based on the point stress criterion.

Dharani, L. R.↗
NASA NTRS1995

Micro-mechanics of micro-composites

The Structural Dynamics branch at NASA LaRC is working on developing an active passive mount system for vibration control. Toward this end a system utilizing piezoelectric actuators is currently being utilized. There are limitations to the current system related to space applications under which it is desired to eliminate deformations in the actuators associated with thermal effects. In addition, a material that is readily formable into complex shapes and whose mechanical properties can be optimized with regards to vibration control would be highly desirable. Microcomposite material are currently under study to service these needs. Microcomposite materials are essentially materials in which particles on the scale of microns are bound together with a polyimide (LaRC Si) that has been developed at LaRC. In particular a micro-composite consisting of LaRC Si binder and piezoelectric ceramic particles shows promise in satisfying the needs of the active passive mount project. The LaRC/ Si microcomposite has a unique combination of piezoelectric properties combined with a near zero coefficient of thermal expansion and easy machinability. The goal of this ASEE project is to develop techniques to analytically determine important material properties necessary to characterize the dynamic properties of actuators and mounts made from the LaRC Si / ceramic microcomposite. In particular, a generalized method of cells micromechanics originally developed at NASA Lewis is employed to analyze the microstructural geometry of the microcomposites and predict the overall mechanical properties of the material. A testing program has been established to evaluate and refine the GMC approach to these materials. In addition, a theory of mixtures analysis is being developed that utilizes the GMC micromechanics information to analyze complex behavior of the microcomposite material which has a near zero CTE.

Donovan, Richard P.↗
NASA NTRS1999

Time Temperature-Precipitation Behavior in An Al-Cu-Li Alloy 2195

Al-Cu-Li alloy 2195, with its combination of good cryogenic properties, low density, and high modulus, has been selected by NASA to be the main structural alloy of the Super Light Weight Tank (SLWT) for the Space Shuttle. Alloy 2195 is strengthened by an aging treatment that precipitates a particular precipitate, labeled as T1(Al2CuLi). Other phases, such as GP zone, (theta)', (theta)", theta, (delta)', S' are also present in this alloy when artificially aged. Cryogenic strength and fracture toughness are critical to the -SLWT application, since the SLWT will house liquid oxygen and hydrogen. Motivation for the Time-Temperature-Precipitation (TTP) study at lower temperature (lower than 350 F) comes in part from a recent study by Chen, The study found that the cryogenic fracture toughness of alloy 2195 is greatly influenced by the phases present in the matrix and subgrain boundaries. Therefore, the understanding of TTP behavior can help develop a guideline to select appropriate heat treatment conditions for the desirable applications. The study of TTP behavior at higher temperature (400 to 1000 F) was prompted by the fact that the SLWT requires a welded construction. Heat conduction from the weld pool affects the microstructure in the heat-affected zone (HAZ), which leads to changes in the mechanical properties. Furthermore, the SLWT may need repair welding for more than one time and any additional thermal cycles will increase precipitate instability and promote phase transformation. As a result considerable changes in HAZ microstructure and mechanical properties are expected during the construction of the SLWT. Therefore, the TTP diagrams can serve to understand the thermal history of the alloy by analyzing the welded microstructure. In the case welding, the effects of thermal cycles on the microstructure and mechanical properties can be predicted with the aid of the TTP diagrams. The 2195 alloy (nominally Al + 4 pct Cu + 1 pct Li + 0.3 pct Ag + 0.3 pct Mg + 0.1 pct Zr) used in this study was received in the form of 1.7 inch thick rolled plates. In brief goal of this study is to develop TTR diagram for the solutiontreated and stretched alloy 2195 from which the precipitation sequence at any service or aging conditions can be preducted.A subgrain boundary TTR diagram is also presented since precipitations at subgrain boundary can control and/or modify a wide veriety of material properties, such as cryogenic fracture toughness.

Chen, P. S.↗
NASA NTRS2011

Unintended Consequences: How Qualification Constrains Innovation

The development and implementation of new materials and manufacturing processes for aerospace application is often hindered by the high cost and long time span associated with current qualification procedures. The data requirements necessary for material and process qualification are extensive and often require millions of dollars and multiple years to complete. Furthermore, these qualification data can become obsolete for even minor changes to the processing route. This burden is a serious impediment to the pursuit of revolutionary new materials and more affordable processing methods for air vehicle structures. The application of integrated computational materials engineering methods to this problem can help to reduce the barriers to rapid insertion of new materials and processes. By establishing predictive capability for the development of microstructural features in relation to processing and relating this to critical property characteristics, a streamlined approach to qualification is possible. This paper critically examines the advantages and challenges to a modeling-assisted qualification approach for aerospace structural materials. An example of how this approach might apply towards the emerging field of additive manufacturing is discussed in detail.

Brice, Craig A.↗
DOE OSTI2024

Latent Pitfalls in Microstructure-Based Modeling for Thermally Aged 9Cr-1Mo-V Steel (Grade 91)

A case study was conducted on a mechanistic model development that predicted tensile strength deterioration with thermal aging of 9Cr-1Mo-V steel in supporting the 60-year design life expected for advanced nuclear reactors. For property prediction beyond practical testing times, mechanistic modeling is highly desired, as it taps into the physics of structure–property relationships and therefore can generate reliable results for extrapolation. Meanwhile, as mechanistic models are often complicated, reflecting the intricacy of microstructure and strengthening mechanisms, pitfalls that are difficult to detect often exist. Here, this paper discusses latent pitfalls that are common in mechanistic modeling or specific in this 9Cr-1Mo-V case development through using the American Society of Mechanical Engineers verification and validation in computational solid mechanics (ASME V&V 10) standard for evaluating credibility of modeling in materials engineering. Suggestions are also made for enhancing reliability of microstructure-based modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2025

An Initial Microstructurally Informed Model of High Burnup Structure Formation in UO 2 Fuel

The microstructure of a UO 2 fuel pellet changes as burnup increases, impacting fuel performance. Predicting and characterizing high burnup structure (HBS) and dark zone formation is a key part of supporting burnup limit extensions for light water reactors. This paper describes a model developed through fitting radially resolved pellet data obtained from recently published microstructural characterization data. The model predicts grain size and grain character, in addition to pore density and size, with fitting dependencies on power history variables. Separately fitting power history variables to microstructural parameters allows for insight into the underlying physical phenomena for future model development. Additionally, experimental data have been correlated to an HBS fraction to facilitate the development of a model capable of predicting a total fuel restructured fraction at the engineering scale. In conclusion, this two-step approach provides a coupling from reactor power history to microstructural data to fractional HBS and creates a basis to model HBS-dependent parameters in a fuel performance code.

High burnup structure↗
NASA NTRS1988

A continuum damage model of fatigue-induced damage in laminated composites

A model is presented which predicts the stress-strain behavior of continuous fiber reinforced laminated composites in the presence of microstructural damage. The model is based on the concept of continuum damage mechanics and uses internal state variables to characterize the various damage modes. The associated internal state variable growth laws are mathematical models of the loading history induced development of microstructural damage. The model is demonstrated by using it to predict the response of damaged AS-4/3502 graphite/epoxy laminate panels.

Harris, Charles E.↗
NASA NTRS1988

Concepts for interrelating ultrasonic attenuation, microstructure, and fracture toughness in polycrystalline solids

Conceptual models are advanced for explaining and predicting empirical correlations found between ultrasonic measurements and fracture toughness of polycrystalline solids. The models lead to insights concerning microstructural factors governing fracture processes and associated stress wave interactions. Analysis of the empirical correlations suggested by the models indicate that, in addition to grain size and shape, grain boundary reflections, elastic anisotropy, and dislocation damping are factors that underlie both fracture toughness and ultrasonic attenuation. One outcome is that ultrasonic attenuation can predict the size of crack blunting or process zones that develop in the vicinity of active cracks in metals. This forms a basis for ultrasonic ranking according to variations in fracture toughness.

Vary, A.↗
NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
DOE OSTI2025

Holistic Microstructure Control Strategies in Photopolymerization‐Induced Phase Separation of Acrylate Systems

Open porous materials, known for their large surface area and interconnected structures, are essential in various applications, including batteries, ion exchange, catalysis, filtration, and electronic waste recycling. A critical aspect of the functionality of porous membranes is the precise control of pore size and morphology. Photopolymerization-induced phase separation (photo-PIPS) offers a convenient and versatile methods for creating porous structures. However, controlling the porous morphology remains challenging due to the complex interplay between thermodynamics, polymerization kinetics, and monomer structures, which makes it difficult to establish the relationship between processing conditions and resulting morphology in photo-PIPS. Herein, a physics-based phase-field model capable of generating and characterizing the microstructures of porous materials based on both average and localized features is developed. Using the phase-field simulations as test bed, the effects of polarity, light intensity, and curing temperature, as well as the previously unexplored roles of chain transfer agents and substrates, on the morphology of the resulting porous microstructure are investigated. Experiments are performed to verify the results predicted by the simulations. This work lays out a comprehensive guide for designing PIPS-derived porous microstructures and offers practical engineering strategies for tailoring microstructure-level topology and size of pores for application-specific needs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Creep and Creep Fracture Modeling with Surrogate Creep Models and the Extended Finite Element Method

Alloy components in advanced nuclear reactors will be subjected to environmental conditions that could include high temperatures, irradiation, and exposure to corrosive salts. These conditions could lead to the formation of crack-like defects, which could grow over time in a mechanism known as creep crack growth (CCG). Predicting growth rates of these defects is important for assessing the safe operating life of advanced reactors. This project documents progress toward developing and testing next-generation data-driven constitutive models for deformation creep. It also documents the application of the extended finite element method in conjunction with surrogate creep models to predict CCG parameters under a variety of conditions. These important incremental developments contribute to the longer-term objective of developing microstructure-aware constitutive models that can be used for predicting creep deformation and CCG at the component scale with improved accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Materials Characterization, Prediction and Control Project: Summary Report on Data Analytics Framework

This report summarizes the activities performed under the data analytics Vertex in the Materials Characterization, Prediction and Control Project funded under laboratory directed research and development at Pacific Northwest National Laboratory. The data analytics Vertex developed models for associating global or local process parameters, microstructural features, and performance properties of friction-stir-processed 316L stainless steel plates. Statistical, machine learning, and deep learning models, as well as generative artificial intelligence approaches, were used to develop the associations between the process-structure-property data streams. These associations formed the basis for predicting global properties of parts manufactured under different process envelopes, providing a basis for predicting performance using data driven as well as physics-informed and physics-constrained approaches. Additionally, the associations were used to predict local process parameters and microstructural features of the product, predictive relationships that have the potential to form the basis of a control framework that could eventually modulate a friction-stir process to maintain product quality.

316L stainless steel↗
DOE OSTI2024

Stress localization investigation of additively manufactured GRCop-42 thin-wall structure

A full-field crystal plasticity (CP) framework is presented for the GRCop-42 alloy to study microscopic mechanical behavior and local stress heterogeneities. The microstructures of additively manufactured (AM) materials are often unique relative to conventionally processed materials, and the local thermal histories drive these differences during the build process. These thermal histories depend on the process parameters (laser power, scan speed, and scan strategy) and the part geometry. Prior research has shown that the mechanical properties of thin-walled structures can vary significantly with wall thickness due to changes in the thermal boundary conditions during manufacturing. It is, therefore, desirable to perform CP simulations based on the phenomenological constitutive model to predict the local mechanical responses induced by microstructural heterogeneities. This work generates representative microstructures based on experimentally collected grain information (i.e., texture) for grain scale stress analysis, and the material constitutive parameters are calibrated using the experimental mechanical testing data. Here, we specifically investigated the effect of crystallographic texture and grain morphologies on the size-dependent mechanical properties of AM GRCop-42. The selection of appropriate material properties for implementing an effective free surface boundary condition and the influence of adjacent buffer layers are also discussed. Analysis of local field results reveals a strong correlation between stress localization and the initial grain orientation. However, no significant relationship between the misorientation of the individual adjacent grains and the average misorientation is observed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

In situ irradiation of spent nuclear fuels

To improve the economics of commercial nuclear reactors, nuclear vendors and utilities are seeking approval for increased burnup usage of the existing nuclear fleet. This is especially critical for meeting the clean energy initiative by the United States Government, Department of Energy (DOE). However, one of the key challenges the nuclear industry faces in this regard is that the regions exposed to high burnup and low temperatures exhibit a fine-grained microstructure with large bubbles known as high-burnup structure (HBS) [1]. The formation of HBS has been correlated to the diminished performance of the reactor, as well as fuel fragmentation and pulverization during transient and accidental conditions [2]. Therefore, it is paramount to understand the mechanisms for HBS formation along with its impact on the properties and performance of nuclear fuels. While existing programs, such as Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Fuel Campaign (AFC) are focusing on evaluating the performance impact of HBS, the physical mechanisms contributing to HBS formation are still not fully understood. In addition, having predictive capabilities and sound understanding of the microstructural evolution of nuclear fuel is essential for accelerated development, qualification, and deployment of new nuclear materials and novel reactor designs for advanced nuclear reactors. There is a lack of consensus among researchers regarding the mechanisms leading to such restructuring observed in HBS. Grain subdivision due to polygonization versus recrystallization, continuous versus discrete recrystallization occurring in tandem or conjunction, etc., have been proposed and debated. In general, it is hypothesized that defect accumulation and dislocation interaction within the grains cause the realignment of dislocations into grain boundaries, leading to the new subgrain formation, which over time transforms into new grains. However, due to the lack of transient data, the importance of fission rate, irradiation, thermal, and stress history of the fuel on the restructuring could not be assessed. In situ microstructural evolution under various irradiation conditions is desired to bridge this gap. Alternatively, phase-field-based models have been developed to capture HBS formation via discrete recrystallization utilizing the classical nucleation approach [3–5]. However, in these models, the grain nucleation criteria are often defined based on empirical relations for burnup and fission gas density leading to dislocation density change. A mechanistic approach to capture the dislocation interaction with the microstructural features leading to grain subdivision is lacking.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗