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DOE OSTI2018

Experiment and simulation study on unidirectional carbon fiber composite component under dynamic 3 point bending loading

In current work, unidirectional (UD) carbon fiber composite hatsection component with two different layups are studied under dynamic 3 point bending loading. The experiments are performed at various impact velocities, and the effects of impactor velocity and layup on acceleration histories are compared. A macro model is established with LS-Dyna for more detailed study. The simulation results show that the delamination plays an important role during dynamic 3 point bending test. Based on the analysis with high speed camera, the sidewall of hatsection shows significant buckling rather than failure. Without considering the delamination, current material model cannot capture the post failure phenomenon correctly. The sidewall delamination is modeled by assumption of larger failure strain together with slim parameters, and the simulation results of different impact velocities and layups match the experimental results reasonable well.

Dynamic 3 point bending, UD CFRP composite, simula↗

DOE OSTI2017

Assessing the Validity of the Simplified Potential Energy Clock Model for Modeling Glass-Ceramics

Glass-ceramic seals may be the future of hermetic connectors at Sandia National Laboratories. They have been shown capable of surviving higher temperatures and pressures than amorphous glass seals. More advanced finite-element material models are required to enable model-based design and provide evidence that the hermetic connectors can meet design requirements. Glass-ceramics are composite materials with both crystalline and amorphous phases. The latter gives rise to (non-linearly) viscoelastic behavior. Given their complex microstructures, glass-ceramics may be thermorheologically complex, a behavior outside the scope of currently implemented constitutive models at Sandia. However, it was desired to assess if the Simplified Potential Energy Clock (SPEC) model is capable of capturing the material response. Available data for SL 16.8 glass-ceramic was used to calibrate the SPEC model. Model accuracy was assessed by comparing model predictions with shear moduli temperature dependence and high temperature 3-point bend creep data. It is shown that the model can predict the temperature dependence of the shear moduli and 3- point bend creep data. Analysis of the results is presented. Suggestions for future experiments and model development are presented. Though further calibration is likely necessary, SPEC has been shown capable of modeling glass-ceramic behavior in the glass transition region but requires further analysis below the transition region.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Three-point bending analysis of doubly clamped silicon nanowire beams; Young's modulus, initial stress, and crystal orientation

A non-linear model is introduced describing the force-deflection relation of doubly clamped beams, including initial stress. Several approximations for the exact model are developed and compared, revealing the importance of considering the initial stress during 3-point bending measurements analysis. A novel approximation is found to be better than others, and both the exact model and this approximation are in perfect agreement with finite element simulations. A brief experimental example of silicon nanowires is presented in which the Young's modulus, the initial stress, and the crystallographic growth orientation are extracted by 3-point bending analysis.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Fracture resistance of hierarchical Cu–Mo nanocomposite thin films

We report the fracture behavior of high-temperature co-sputtered Cu/Mo nanocomposite thin films was investigated through in situ 3-point bend testing of pre-notched microbeams in SEM. The as-synthesized nanocomposites present hierarchical nano/microstructures composed of a matrix of phase-separated Cu–Mo with nanoscale ligaments dispersed with sub-micron scale Cu-rich islands containing Mo nano-precipitates. Results show a significant crack growth resistance in the hierarchical nanocomposite, several times higher than that measured in Cu/Mo nanoscale multilayers. Based on electron microscopy characterization, three mechanisms of crack growth resistance in the hierarchical structures are proposed: crack bridging by the Cu-rich layer, crack deflection via shear along the Cu/Mo interface, and multiple cracking. This work demonstrates an approach to increase toughness in high strength nanocomposites through interface micro-structure design.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Experimental data for damage mechanics simulation challenge

While there are many computational approaches for simulating damage in rock and other materials, few have been ground truth tested with either known experimental data or with blind data sets. Here, in this work, we present a bench-mark laboratory data set for a damage mechanics challenge to compare computational approaches on damage evolution in brittle-ductile materials. The samples were fabricated through additive manufacturing to produce repeatable specimens designed to fail in controlled ways. The failure was induced in the samples using a 3-point bending test to produce different Modes such as Mode I and mixed Modes including I-II, I-III and I-II-III Modes to generate a calibration data set and a blind challenge data set. Data collected included spatial and temporal measurements from traditional digital load–displacement sensors, 2D digital image correlation measurement to map surface deformations, 3D X-ray microscopy to ground-truth the crack-failure geometry, and laser profilometry to capture surface roughness. The data sets are available, on a data repository, to the community to advance computational models to improve our ability to predict damage in brittle-ductile materials.

3-point bending↗

DOE OSTI2015

Comparison of ring compression testing to three point bend testing for unirradiated ZIRLO cladding

Safe shipment and storage of nuclear reactor discharged fuel requires an understanding of how the fuel may perform under the various conditions that can be encountered. One specific focus of concern is performance during a shipment drop accident. Tests at Savannah River National Laboratory (SRNL) are being performed to characterize the properties of fuel clad relative to a mechanical accident condition such as a container drop. Unirradiated ZIRLO tubing samples have been charged with a range of hydride levels to simulate actual fuel rod levels. Samples of the hydrogen charged tubes were exposed to a radial hydride growth treatment (RHGT) consisting of heating to 400°C, applying initial hoop stresses of 90 to 170 MPa with controlled cooling and producing hydride precipitates. Initial samples have been tested using both a) ring compression test (RCT) which is shown to be sensitive to radial hydride and b) three-point bend tests which are less sensitive to radial hydride effects. Hydrides are generated in Zirconium based fuel cladding as a result of coolant (water) oxidation of the clad, hydrogen release, and a portion of the released (nascent) hydrogen absorbed into the clad and eventually exceeding the hydrogen solubility limit. The orientation of the hydrides relative to the subsequent normal and accident strains has a significant impact on the failure susceptability. In this study the impacts of stress, temperature and hydrogen levels are evaluated in reference to the propensity for hydride reorientation from the circumferential to the radial orientation. In addition the effects of radial hydrides on the Quasi Ductile Brittle Transition Temperature (DBTT) were measured. The results suggest that a) the severity of the radial hydride impact is related to the hydrogen level-peak temperature combination (for example at a peak drying temperature of 400°C; 800 PPM hydrogen has less of an impact/ less radial hydride fraction than 200 PPM hydrogen for the same thermal history) and b) for critical strains in post drying handling, storage and accident conditions the 3 point bend strain tolerance is less affected by radial hydrides than the conventional ring compression test (the radial hydride related Quasi DBTT associated with a three point bend straining is lower (better) than that measured by the ring compression tests).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Testing the 2-3 Shear Strength of Unidirectional Composite

In this study, the objective was to measure the “out-of-plane” 2-3 shear strength of unidirectional composite, working within constraints in supplied material geometry. Unidirectional carbon/epoxy composite material was tested using a sandwich-type beam specimen under 3-point bending with a low span-to-thickness ratio to achieve failure under 2-3 shear. Specimens were carefully designed to deliberately cause shear failure near the midplane, avoiding other possible failure mechanisms. A photoelastic coating and post-mortem microscopy were used to verify failures. Results were compared with a simple analytical description of failure and found to have good agreement. Notably, this approach was able to accommodate the limitations of the supplied material (thin sheets) while still providing an accurate means of obtaining the F23 shear strength of the material. The results also imply the possibility of testing the transverse tensile strength (F2t) in lieu of performing a shear test, which is far simpler, and inferring the out-of-plane shear strength F23.

Fenner, Joel S.↗

DOE OSTI2018

A three-dimensional meso-scale approach to concrete fracture based on combined DEM with X-ray μCT images

Highlights: • We investigate fracture in concrete beams subjected to 3-point bending. • We use a discrete element method (DEM) to capture fracture. • Concrete is described as 4-phase material. • Evolution of micro-structural phenomena is investigated. • The 3D results are carefully compared with the 2D ones. - Abstract: The paper shows three-dimensional (3D) numerical mesoscopic results on progressive concrete fracture at aggregate level in a notched concrete beam under bending. A classical particle discrete element method was used to capture fracture in concrete. Heterogeneity was taken into account with a 4-phase concrete description: aggregate, cement matrix, macro-voids and interfacial transitional zones. Both the real shape and location of aggregate particles in concrete were assumed in DEM analyses based on X-ray μCT scans. A satisfactory agreement in terms of the vertical force versus crack mouth opening displacement evolution and crack geometry was achieved between DEM analyses and own laboratory tests. The evolution of broken contacts, contact normal forces, particle rotations, internal energies was studied at the aggregate level. The 3D results were also carefully compared with the 2D ones. The 3D model proved to be a promising simulation tool in predicting concrete fracture at the mesoscopic and macroscopic level.

36 MATERIALS SCIENCE↗

DOE OSTI2024

The damage Mechanics challenge Results: Participant predictions compared with experiment

In this article, We present results from a recent exercise where participating organizations were asked to provide model-based blind predictions of damage evolution in 3D-printed geomaterial analogue test articles. Participants were provided with a range of data characterizing both the undamaged state (e.g., ultrasonic measurements) and damage evolution (e.g., 3-point bending, unconfined compression, and Brazilian testing) of the material. In this paper, we focus on comparisons between the participants’ predictions and the previously secret challenge problem experimental observations. We present valuable lessons learned for the application of numerical methods to deformation and failure in brittle-ductile materials. The exercise also enables us to identify which specific types of calibration data were of most utility to the participants in developing their predictions. Further, we identify additional data that would have been useful for participants to improve the confidence of their predictions. Consequently, this work improves our understanding of how to better characterize a material to enable more accurate prediction of damage and failure propagation in natural and engineered brittle-ductile materials.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Enhanced biomechanical performance of additively manufactured Ti-6Al-4V bone plates

As the global trauma fixation devices market expands rapidly, it is imperative to improve the production of fixation devices through enhanced design accuracy and fit for best performance and maximum patient comfort. Selective laser melting (SLM) is one of the mature additive manufacturing methods, which provides a viable route for the rapid production of such devices. In this work, the ability of SLM to produce near-net-shape parts, as desired for medical implants, was utilized for the fabrication of bone plates from Ti-6Al-4V alloy powder. Martensitic microstructure obtained after the printing of alloy resulted in poor ductility, limiting its application in the field of orthopedics. A specially designed repeated cyclic heating and cooling close to but below the β-transus was used to transform from acicular to a bimodal microstructure without the need for plastic deformation prior to heat treatment for improving the ductility. Bone plates subjected to this heat treatment were mechanically tested by means of tensile and 3-point bend tests and demonstrated large improvement in ductility, and the values were comparable to those similar plates prepared from wrought alloy. Other important properties required for implants were assessed, such as corrosion resistance in simulated body fluid and cytocompatibility in vitro using MC3T3-E1 cells. These results for the bone plate after heat treatment were excellent and similar to those of the additively manufactured and wrought plates. Taken together, the performance of the additively manufactured bone plates after subjecting to heat treatment was similar to those of bone plate manufactured using wrought alloy. These results have important implications for the fabrication of patient-specific metallic orthopedic devices using SLM without compromising their biomechanical performance by subjecting them to a tailored heat treatment.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Effects of developmental exposure to perfluorooctanoic acid (PFOA) on long bone morphology and bone cell differentiation

Perfluorooctanoic acid (PFOA) is a ubiquitous and persistent environmental chemical, which has been used extensively due to its stability and surface tension-lowering properties. Toxicological effects include induction of neonatal mortality and reproductive toxicity. In this study, pregnant C57BL/6 mice were exposed orally to 0.3 mg PFOA/kg/day throughout pregnancy, and female offspring were studied at the age of 13 or 17 months. Morphometrical and biomechanical properties of femurs and tibias were analyzed with micro-computed tomography and 3-point bending, and bone PFOA concentrations were determined by mass spectrometry. The effects of PFOA on bone cell differentiation were studied in osteoclasts from C57BL/6 mice and in the MC3T3 pre-osteoblast cell line. PFOA exposed mice showed increased femoral periosteal area as well as decreased mineral density of tibias. Biomechanical properties of these bones were not affected. Bone PFOA concentrations were clearly elevated even at the age of 17 months. In osteoblasts, low concentrations of PFOA increased osteocalcin (OCN) expression and calcium secretion, but at PFOA concentrations of 100 μM and above osteocalcin (OCN) expression and calcium secretion were decreased. The number of osteoclasts was increased at all PFOA concentrations tested and resorption activity dose-dependently increased from 0.1–1.0 μM, but decreased at higher concentrations. The results show that PFOA accumulates in bone and is present in bones until the old age. PFOA has the potential to influence bone turnover over a long period of time. Therefore bone is a target tissue for PFOA, and altered bone geometry and mineral density seem to persist throughout the life of the animal. - Highlights: • Bone is a target tissue for PFOA both in vivo and in vitro. • Maternal exposure during pregnancy results in PFOA accumulation in bone of the offspring. • PFOA is present in bones until the old age. • PFOA causes mild alterations in bone morphometry and decreases bone mineral density. • Low PFOA concentrations stimulate the resorption activity of osteoclasts.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2014

PBX 9502 Multimode Damage Accumulation Cycles-to-Failure Study

In FY13, we performed a detailed cycles-to-failure study of PBX 9502 using 3- point bend specimens. In that study we examined the effect of temperature and cyclic frequency on the failure behavior of PBX 9502. We identified cycles-to-failure curves for samples tested at -20°C, ~19°C and 50°C and at cyclic frequencies of 0.0001 up to 1-Hz. We also did cyclic conditioning of parts in an effort to establish damage accumulation criteria that could then be used in predictive models. As follow-on to that work, in FY14 we have added multimode cycles-to-failure to our test suite. Work this year re-established the baseline cycles-to-failure behavior of the PBX 9502 material tested round ~19°C at 1-Hz and also looked at damage accumulation under a multimode loading environment. This fresh baseline development was performed to remove any time related or test rig related variables. The multimode loading was done because real-world applications are not mono-modal and we desire for our predictive capability to be robust and include more complex, realistic scenarios. In the following sections we briefly describe the test setup, we provide a summary of the new baseline results and we show the multimode cycles-to-failure data and how it compares to the mono-modal test data.

42 ENGINEERING↗

DOE OSTI2022

Irradiated stainless steel 347 and irradiated, welded, and hydrogen charged Zircaloy-4 property data for the target solution vessel and support lines of SHINE

In support of the reactor-vessel development effort of SHINE medical technologies, irradiation of its structural materials and post-irradiation testing have been performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. This irradiation was performed on welded and unwelded AISI 347 steel and Zircaloy-4 samples at low temperature (~60°C) in contact with the reactor coolant. Hardness, Charpy, and tensile data have been taken from all cases of unirradiated specimens, while post-irradiation tensile and hardness data have been taken from AISI 347 base metal and Zircaloy-4 base metal and weld specimens so far. Additionally, 3-point bend data have been taken from explosion-welded specimens. The expected changes to hardness, yield strength, ultimate tensile strength, uniform elongation, and total elongation as a result of the low temperature and low dose neutron irradiation are reported here.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturer (OEM)s. In addition to high strength for safety requirements, superior Self-Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight, and thus improving energy efficiency. The purpose of this project is to extend and validate an existing finite element code, which is based on the Contractor developed macro-micro multi-scale modeling approach, to numerically simulate the three-point bending and clinch test and study the influences of material microstructural characteristics and phase properties on the rivetability. The macro-micro modeling approach begins with a sample scale model and identify the location, which is mostly prone to failure, the deformation history of the boundaries of that location calculated will be used to drive a microstructure-based sub-models where the material microstructure and microscale properties are considered. Using this approach, the wrap-bending failure for two Al alloys are correctly predicted for the first time. This will start with phase I effort of building a framework of macro-micro three point bending test and clinch test of Al10SiMgMn HPDC alloy in the as-cast and T7 heat treated conditions. Those results will then be validated with experimental test results. The phase II effort will involve the utilization of the knowledge learned in phase I to establish the quantitative correlation between the microstructure characteristics and the riveting performance, which will be further used to guide the optimization of HPDC Al alloy microstructure using heat treatment process to achieve sufficient rivetability to join large thin-wall HPDC alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2019

The Effect of Calcium on the Cohesive Strength and Flexural Properties of Low-Methoxyl Pectin Biopolymers

Pectin binds the mesothelial glycocalyx of visceral organs, suggesting its potential role as a mesothelial sealant. To assess the mechanical properties of pectin films, we compared pectin films with a less than 50% degree of methyl esterification (low-methoxyl pectin, LMP) to films with greater than 50% methyl esterification (high-methoxyl pectin, HMP). LMP and HMP polymers were prepared by step-wise dissolution and high-shear mixing. Both LMP and HMP films demonstrated a comparable clear appearance. Fracture mechanics demonstrated that the LMP films had a lower burst strength than HMP films at a variety of calcium concentrations and hydration states. The water content also influenced the extensibility of the LMP films with increased extensibility (probe distance) with an increasing water content. Similar to the burst strength, the extensibility of the LMP films was less than that of HMP films. Flexural properties, demonstrated with the 3-point bend test, showed that the force required to displace the LMP films increased with an increased calcium concentration ( p < 0.01). Toughness, here reflecting deformability (ductility), was variable, but increased with an increased calcium concentration. Similarly, titrations of calcium concentrations demonstrated LMP films with a decreased cohesive strength and increased stiffness. We conclude that LMP films, particularly with the addition of calcium up to 10 mM concentrations, demonstrate lower strength and toughness than comparable HMP films. These physical properties suggest that HMP has superior physical properties to LMP for selected biomedical applications.

Biochemistry & Molecular Biology↗

DOE OSTI2021

Three Sheet Al alloy assembly for automotive application

An update on joint characterization of three sheet friction stir lap welds (FSLW) in three aluminum alloys (7xxx, 5xxx, and 6xxx) for automotive assembly application is presented. Welding speed of 0.3-2.9m/min was used with pin length >5mm with the aim to reduce upturn hooking on the retreating side and avoid wormhole defect on the advancing side. Joints were also made in to enable T peel and U peel testing. Stitch welds were used to understand effects of weld length and ramp length on T peel performance. Hat sections were joined for 3-point bending and axial crush testing and tested with promising results. Several key issues that require further investigations are identified including flash management near the trim edge, weld quality with limited clamping, tool failures at speeds greater than 0.5m/min, and propensity of incipient melting for 7xxx stack-up.

Upadhyay, Piyush↗

DOE OSTI2019

Loading Capabilities of Irradiated 3-D Printed Polymers

Gamma radiation is the emission of a high-energy photon from a radioactive source. The photon then interacts with an atom potentially damaging it. While time has shown that gamma radiation has a little effect on metals, the same cannot be said about plastic. The use of these types of materials in radioactive areas has increased for many reasons ranging from the weight difference between plastics and metals to the costs associated with doing so. For example, a potential use for radiation resistant plastics could be longer lasting, cost effective, and light weight radiation detection devices sent to probe an area that may present unsafe conditions for humans to survey. For these reasons and more, finding a plastic polymer that can withstand radiation for an extended period of time would make a great impact on the nuclear industry. In this experiment, two different polymers will undergo a series of strength tests before and after being exposed to radiation after different amounts of time up to two weeks. There are two sets of plastic polymers that will be used. Each set will consist of an nonirradiated, control subset, and subsets subject to radiation for one day, one week, and two weeks. The radiation source is 1100 Ci cobalt- 60. The specimens are placed on a foam platform such that they will be exposed as evenly as possible. They are then lowered into the radiation chamber where they are surround by cobalt-60 sources and irradiated for the given amount of time. The specimens will be tested for tensile strength and flexural strength according to ASTM standards. For tensile testing, the specimen has a 'dog bone' shape. The specimen is gripped at the wide ends, and pulled away from the center at a constant rate until failure. To test flexural strength, the specimens will be subject to a 3-point bend test. The specimen is held in place by three points, center top side and both ends bottom side. Load is applied at a constant rate on the center of the specimen until failure. The calculations to be considered for comparison after performing these tests include the tensile strength and stress, elongation, flexural stress and strain, and elasticity. Once these tests are completed, testing specimens that have been 3D printed with different print orientations will be considered and tested. The results from both experiments will help create strong, radiation resistant products in a expeditious manner that could really push the current limitations and expand the use of radiation resistant material.

36 MATERIALS SCIENCE↗