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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here we report an initial reproducibility experiment focused on contour method data analysis and residual stress calculation. The experiment uses surface topography data from a physical process simulation of elastic-plastic beam bending. The simulation provides surface topography, for input to the contour method data analysis, as well as a known residual stress field with 130 MPa peak magnitude. Additionally, to increase realism, noise and specific artifacts are added to the topography data. A group of participants received the topography data (without the known residual stress), independently analyzed the data, and submitted results as a two-dimensional residual stress field. Analysis of submissions provides a group average residual stress field and the spatial distribution of reproducibility standard deviation. The group average residual stress agrees with the known stress in magnitude and spatial trend. The reproducibility standard deviation ranges from 2 to 54 MPa over the measurement plane, with an average of 5.4 MPa. Reproducibility standard deviation is smaller in the cross-section interior (≤ 5 MPa), modest near local extrema in the stress field (5 to 10 MPa), and larger near the cross-section boundaries (10 to 30 MPa). Overall, the largest values of reproducibility standard deviation (up to 54 MPa) occur in limited areas where artifacts had been added to the topography data; while some participants identified and removed these artifacts, some did not, leading to systematic differences that elevated the standard deviation.

42 ENGINEERING↗
DOE OSTI2018

Examination of Mean Stress Calculation Approaches in Rock Mechanics

The mean stress, as a fundamental statistical property of a group of stress data, is essential for stress variability characterisation. However, currently in rock mechanics, the mean stress is customarily and erroneously calculated by separately averaging the principal stress magnitudes and orientations. In order to draw the attention of our community to the appropriate approach for stress variability characterisation, here we compare the customary scalar/vector mean with that obtained by the mathematically rigorous tensorial approach—the Euclidean mean. Calculation of mean stress using both a small group of actual in situ stress measurement results and a large group of simulated stress data (obtained using the combined finite– discrete element method, FEMDEM) demonstrates that the two approaches yield different results. Further investigation of these results shows that the scalar/vector approach may yield non-unique and non-orthogonal mean principal stresses, and these may deviate significantly from those of the Euclidean mean. Our calculations and comparisons reveal that the scalar/ vector approach is deficient because it processes the principal stress magnitudes and orientations separately as independent quantities and ignores the connection between them. Conversely, the tensorial approach appropriately averages the tensors that simultaneously carry not only the information of stress magnitudes and orientations, but also the inherent relations between them. Therefore, arbitrarily using scalar/vector mean stress of in situ stress measurements as input in further rock engineering analyses may yield significantly erroneous results. Finally, we advise that stress data should be statistically processed in a tensorial manner using tensors referred to a common Cartesian coordinate system.

58 GEOSCIENCES↗
DOE OSTI2025

WHOLESCALE - Water & Hole Observations Leverage Effective Stress Calculations And Lessen Expenses (Final Technical Report 2020 - 2024)

The WHOLESCALE acronym stands for Water & Hole Observations Leverage Effective Stress Calculations and Lessen Expenses. The goal of the WHOLESCALE project is to simulate the spatial distribution and temporal evolution of stress in the geothermal system at San Emidio in Nevada, United States. To reach this goal, the WHOLESCALE team has developed a methodology to incorporate and interpret data from four methods of measurement into a multi-physics model that couples thermal, hydrological, and mechanical (T H-M) processes. The WHOLESCALE team has applied this methodology at the San Emidio geothermal field, located ~100 km north of Reno, Nevada in the northwestern Basin and Range province. The WHOLESCALE team includes 30 individuals working at two universities, two national laboratories, and one industry partner. Two master-degree students and five post-doctoral researchers have gained professional experience and earned partial financial support via the WHOLESCALE project. The WHOLESCALE team has taken advantage of the perturbations created by changes in pumping operations during planned shutdowns in 2016, 2021, and 2022 to infer temporal changes in the state of stress in the geothermal system at San Emidio, Nevada, U.S. The WHOLESCALE results support the working hypothesis that increasing pore-fluid pressure reduces the effective normal stress acting across fault zones. During normal operations, pumping in deep production wells decreases fluid pressures and thus increases the effective normal stresses on faults, reducing microseismicity. During planned shutdowns, the cessation of production increases pore-fluid pressure and reduces effective normal stress. The WHOLESCALE products generated during the 4-year period between 2020 and 2024 include: three articles published in the open-access, peer-reviewed scientific literature, two master’s theses, 20 presentations or papers at scientific conferences, and 17 data sets available on public repositories. The WHOLESCALE project has been completed in two phases that included three performance periods separated by two Go/No-go Stage Gate Reviews. Tasks were classified by data type (i.e., Geologic Structure, Borehole, Geodesy, Hydrology, Seismology, and Modeling). The first phase of the project started July 31, 2020 and included ongoing project coordination (Task 1), a project kickoff (Task 2), analysis of existing data (Task 3), development of the initial stress model & deployment design (Task 4), and Go/No-go Decision Point #1 (Task 5). Phase II began with implementing the 2022 deployment (Task 6), followed by Go/No-go Decision Point #2 (Task 7) The remainder of Phase II consisted of analyzing data collected during deployment (Task 8), calibration of the stress model on all observations (Task 9), and the Final Review (August 23, 2024) & Reporting (Task 10).

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Evaluation of proposed Section III Division 5 Class B rules: Piping example problem

Evaluation of proposed Section III Division 5 Class B rules: Piping example problem to be presented include Z pipe geometry and model problem statement, Z pipe loads and design inputs problem statement, Primary Stress Limit overview, Primary stress limit pseudo yield stress calculation, Primary stress limited factored load procedure, Strain limit evaluation composite load cycle, Strain limit evaluation pseudo yield stress, Strain limit evaluation strain limit criteria and ratcheting check, Creep fatigue damage evaluation overview, Creep fatigue damage evaluation alternating stress calculations, Creep fatigue damage evaluation lower bound stress, Creep fatigue damage evaluation stress relaxation history, Creep fatigue damage evaluation damage fractions, and Recommendations to consider for Z-pipe problem.

42 ENGINEERING↗
DOE OSTI2016

Calculation of Debye-Scherrer diffraction patterns from highly stressed polycrystalline materials

Calculations of Debye-Scherrer diffraction patterns from polycrystalline materials have typically been done in the limit of small deviatoric stresses. Although these methods are well suited for experiments conducted near hydrostatic conditions, more robust models are required to diagnose the large strain anisotropies present in dynamic compression experiments. A method to predict Debye-Scherrer diffraction patterns for arbitrary strains has been presented in the Voigt (iso-strain) limit [Higginbotham, J. Appl. Phys. 115, 174906 (2014)]. Here, we present a method to calculate Debye-Scherrer diffraction patterns from highly stressed polycrystalline samples in the Reuss (iso-stress) limit. This analysis uses elastic constants to calculate lattice strains for all initial crystallite orientations, enabling elastic anisotropy and sample texture effects to be modeled directly. The effects of probing geometry, deviatoric stresses, and sample texture are demonstrated and compared to Voigt limit predictions. An example of shock-compressed polycrystalline diamond is presented to illustrate how this model can be applied and demonstrates the importance of including material strength when interpreting diffraction in dynamic compression experiments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Mechanical Safety Subcommittee Guideline for Design of Thin Windows Regarding Roark’s Edge Condition Coefficient

An error was found in an edge stress coefficient used to calculate stresses in thin windows. This error is present in “Roark’s Formulas for Stress and Strain” 7th and 8th Edition. The 6th Edition is correct. This guideline specially discusses a major difference in regards to a coefficient used in calculating the edge stress in “Roark’s Formulas for Stress and Strain” 6th Edition compared to the 7th and 8th Editions. In Chapter 10: Flat Plates under “Circular plates under distributed load producing large deflections,” Case 3, which is “Fixed and held. Uniform pressure q over entire plate.” The coefficient for a fixed edge condition in the 6th Edition1 K4 = 0.476 while in the 7th and 8th Edition2, the coefficient is 1.73 which is significant difference.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

A recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness. Herein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness. Near-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness. Measured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter. The new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

42 ENGINEERING↗
DOE OSTI2025

FY25 status report on the addition of candidate materials in Class B Code Case

This report provides the time-dependent allowable stress calculation strategy leveraging the limited creep rupture tests data generated to support the allowable stress for 100,000 hours in American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section II, Part D. A variable confidence index procedure to extrapolate material properties to support 500,000 hours design life is discussed. Time-dependent allowable stresses for Class B component design and analysis are presented for Grade 1 and Grade 2 of Alloy 625. The presented data extrapolation and allowable stress calculation method will support new material addition using limited creep rupture data in the new ASME Boiler and BPVC, Section III, Division 5, Class B rules.

Part D↗
DOE OSTI2023

MOOSE Optimization Module Overview: Application to Residual Stress Inversion in Nuclear Fuel Plates

Manufacturing methods, material selections and unique plate geometries used in low enriched uranium plate fuels for the High Performance Research Reactor (HPRR) have led to concerns about the residual stresses effect on bond strength of the fuel/cladding interfaces and overall fuel performance under irradiation. The current HPRR plate fuel test program performed residual stress calculations using the contour method with experimental displacement data obtained by incrementally cutting the plate fuel. In this work, we use a gradient based inverse optimization module developed within the MOOSE framework to estimate normal and shear residual stresses within the plate fuels using displacement data taken from a cut placed in the HPRR fuel plate. These results are verified against residual stress calculations obtained from the contour method. The inversion protocol used in this work utilizes two meshes to separately discretize the physics and parameter space. This allows a fine mesh to be used to fully resolve the physics and geometry of the forward problem. A coarser mesh is used to resolve the parameter space with spatially varying mesh density determined from a sensitivity analysis. The adaptive resolution of the parameter space essentially has the effect of regularization as it is designed to achieve the bias-variance tradeoff.

42 ENGINEERING↗
DOE OSTI2018

Enhancing the tensile properties of EBM as-built thin parts: Effect of HIP and chemical etching

Highlights: • The EBM process leads to important cross section variations in thin parts. • Stress calculation must be based on the average section in order to be relevant. • As-built state has a detrimental effect on every mechanical property. • Mechanical properties of machined samples are met with chemical etching. • HIP has a beneficial effect on the ductility. - Abstract: As-built Ti-6Al-4 V thin parts were manufactured using Electron Beam Melting (EBM) and characterized by optical microscopy and laboratory X-ray tomography in order to observe their microstructure, pore distribution and surface aspect. Chemical etching and HIP post-treatments were applied to as-built samples and their effect on the material and static mechanical properties were studied. Tensile tests were performed on both as-built and post-treated samples and their results compared to the ones reported in the literature for machined EBM samples. Because of the significant variations of the cross section observed along the gauge length, the calculation of the tensile stresses is not straightforward. Three simple sections were measured from the tomography scans. The average section along the gauge length was considered as the most suitable. The tensile mechanical properties of the as-built samples were studied and a detrimental effect of the surface state on the yield strength, ultimate tensile strength and elongation to failure was observed. Smoothing of the surface irregularities induced by chemical etching provoked an increase of those mechanical properties whereas the change of the microstructure generated by the HIP treatment leads to a decrease of the material strength that goes along with an increase of the ductility. Down scaling factors were proposed in order to take into account the sample state, as-built or post-treated.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Cantilever testing of sintered-silver interconnects

Cantilever testing is an underutilized test method from which results and interpretations promote greater understanding of the tensile and shear failure responses of interconnects, metallizations, or bonded joints. The use and analysis of this method were pursued through the mechanical testing of sintered-silver interconnects that joined Ni/Au-plated copper pillars or Ti/Ni/Ag-plated silicon pillars to Ag-plated direct bonded copper substrates. Sintered-silver was chosen as the interconnect test medium because of its high electrical and thermal conductivities and high-temperature capability—attractive characteristics for a candidate interconnect in power electronic components and other devices. Deep beam theory was used to improve upon the estimations of the tensile and shear stresses calculated from classical beam theory. The failure stresses of the sintered-silver interconnects were observed to be dependent on test-condition and test-material-system. In conclusion, the experimental simplicity of cantilever testing, and the ability to analytically calculate tensile and shear stresses at failure, result in it being an attractive mechanical test method to evaluate the failure response of interconnects.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High-Field Ignition-Capable Stellarator i-ASTER: Initial Structural Evaluation

i-ASTER is a preliminary conceptual design of a high-field pulsed experimental stellarator aimed essentially at achieving and understanding plasma ignition. The averaged magnetic field on the axis of i-ASTER.v1 is B ~ 10 T and the plasma volume is 30 m 3 . A toroidal monolithic support structure, which is located externally to the modular coils, is defined to accurately arrange the coils and withstand the magnetic Lorentz forces from the high magnetic fields. The magnetic field in the coils and the resulting Lorentz forces on the coils were calculated and utilized for the stress calculation in monolithic support of constant thickness. Subsequently, a monolithic support of variable thickness is proposed and studied. The thickness of the structure is variable and adjusted to the magnitude of the mechanical stress in each area of the toroidal structure so as to smooth the stresses while minimizing the quantity of material used. A fabrication method for the monolithic structure has been tested. For that, a scaled-down mock-up of one period of stellarator has been additively manufactured and strengthened with fiber-reinforced resin. Unsurmountable difficulties have not been found for this fabrication method.

Queral, Vicente↗
DOE OSTI2024

A weak subducting slab at intermediate depths below northeast Japan

Knowledge of the state of stress in subducting slabs is essential for understanding their mechanical behavior and the physical processes that generate earthquakes. Here, we develop a framework which uses a high-resolution focal mechanism catalog to determine the change in the position of the neutral plane before and after the M9 Tohoku-oki earthquake to determine that the deviatoric stress within the slab at intermediate depths must be very low (~1 MPa). We show that by combining the static stress calculated from coseismic slip distributions with the stress orientations before and after the mainshock, we can determine the full deviatoric stress tensor within the subducting slab at intermediate depths. These results preclude earthquake source mechanisms that require large background driving stresses, favoring a mechanically weak subducting slab, thus providing quantitative constraints on the physical processes that generate intermediate-depth earthquakes.

58 GEOSCIENCES↗
DOE OSTI2021

A workflow to assess the efficacy of brine extraction for managing injection-induced seismicity potential using data from a CO 2 injection site near Decatur, Illinois

Injection of CO 2 for storage in a geologic formation increases pore pressure and alters in situ stresses. Depending on the orientation of any existing fault and fracture planes, such as critically stressed planes, this stress alteration will modify normal stresses acting on planes and could result in frictional sliding and release stored energy in the form of seismicity. Brine extraction (BE) is a technique that can be applied prior to, or during, CO 2 injection to reduce pore pressure for increasing storage capacity and, potentially, for reducing the likelihood of frictional sliding. Here a workflow is described to assess the efficacy of BE for mitigating frictional sliding (i.e., seismicity) during injection and entails: site characterization, stress calculations and failure assessment, static and dynamic modeling, and BE operational planning. Site characterization describes the stress field used to calculate the Coulomb Failure Function (CFF) that constrains allowable pore pressure changes and injection rates in the numerical simulation of CO 2 injection scenarios. The inclusion of BE in the workflow allows for determination of the potential need for pressure reduction, and evaluation of the effectiveness of this operation. Example application of the workflow using an injection field dataset near Decatur, IL, provides insight on fracture planes and stresses at the site, formation properties and the impact of variable CO 2 injection-rate targets on whether BE plans are required. The study workflow indicates that BE could enhance CO 2 injection rate by 39% and correspondingly reduce the potential for injection-induced seismicity as indicated by a reduction in CFF.

58 GEOSCIENCES↗
DOE OSTI2021

Projected Seismic Activity at the Tiger Stripe Fractures on Enceladus, Saturn, From an Analog Study of Tidally Modulated Icequakes Within the Ross Ice Shelf, Antarctica

Abstract Dissipation of tidal energy is expected to generate seismicity on icy‐ocean worlds; however, the distribution and timing of this seismic activity throughout an orbital cycle is not known. We used new observations from an icy‐ocean‐world analog environment on Earth to examine the relationship between tidally driven tensile stress and seismic activity within an ice shell. We investigated a pair of rifts within Antarctica's Ross Ice Shelf which are tidally stressed in a manner analogous to the orbital cycle of tidal stress experienced by Enceladus' Tiger Stripe Fractures. We found that seismic activity at the Antarctic rifts is sensitive to both the amplitude and the rate of tensile stress across the rifts. We combined these findings with calculated stress values along Enceladus' Tiger Stripe Fractures to predict seismic‐activity levels expected along the ice‐shell fractures. We predict a peak in seismicity along the four Tiger Stripe Fractures when Enceladus is 90°–120° past pericenter in its orbit around Saturn, at which point tensile stresses would reach ∼2/3 of their maximum value. We also used the magnitude distribution of icequakes along Antarctic rifts to investigate implications for the likely size of stick‐slip rupture patches along icy faults on Enceladus. Our findings predict that the Tiger Stripe Fractures should produce sustained, low‐magnitude seismic events that involve rupture along discrete portions of each fracture's total length. We predict that seismicity would fall to 50% of peak levels when stresses across the Tiger Stripe Fractures are dominantly compressional.

Olsen, Kira G.↗