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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Energy Budget of Brittle Fracturing in Granite Under Stress Relaxation and Creep

Creep and relaxation are the two major time-dependent fracturing processes in rocks. While a considerable amount of research has been done in understanding these two mechanisms, critical gaps remain regarding how different energy components evolve during time-dependent fracturing processes in rocks. In this study, a series of relaxation and creep experiments were conducted on prismatic Barre granite specimens in the laboratory to estimate the energy budget of brittle fracturing in granite. For the input energy, the work done by the machine (W) is calculated and for the output energy the radiated seismic energy (E R ), released in the form of acoustic emissions (AEs), is calculated as the only measurable output energy component in the conducted experiments. The low-frequency plateau (Ω 0 ) and corner frequency (f 0 ) for each AE waveform was estimated by fitting the observed AE spectra with the theoretical spectra using the Omega model. These parameters were used to estimate the seismic moments (M 0 ) based on the radiation pattern for the double couple (shear) and non-double-couple (non-shear) events. The range of f 0 and M 0 varied from 150 to 750 kHz and 10 –4 to 10 –1 N m, respectively. Moment magnitude (M w ) varied in a wider range from –9 to –6 in creep and –8.5 to –7 in relaxation. Stress drops (Δ σ ) and source radius (r) were estimated for the AEs using Brune’s model. Here, the results report on three primary observations: (1) the effects of different source mechanisms on the estimated source parameters showed that M 0 and Δ σ were higher for DC events as compared to NDC in both relaxation and creep. (2) The radiation efficiency in the case of creep is 70% higher as compared to relaxation and, (3) the stress drop estimated in relaxation and creep demonstrated a breakdown in scaling with the seismic moment.

58 GEOSCIENCES↗
DOE OSTI2024

Nanoindentation Stress Relaxation to Quantify Dislocation Velocity–Stress Exponent

This work reports a new methodology using indentation stress relaxation to characterize the dislocation velocity–stress exponent. Through the indentation stress relaxation process, the dislocation structure builds up at the rate governed by dislocation velocity, which is a function of the externally applied stress. The relationship between the dislocation velocity and stress can thus be derived from the indentation stress relaxation data of the stress as a function of time. In this study, instrumented nanoindentation stress relaxation experiments were performed on pure aluminum samples, following three different initial displacement rates of 100, 400, and 800 nm/s. Based on the scaling properties of dislocation kinetics, the data were interpreted to derive a dislocation velocity–stress exponent of 2.5 ± 0.5 for room-temperature aluminum. Crystal plasticity finite-element simulations were performed to illustrate the sensitivity of the proposed nanoindentation stress relaxation methodology to the dislocation velocity–stress exponent value.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

How Does the Rate of Chain Exchange Relate to Stress Relaxation in Triblock Copolymer Networks?

The relationship between macroscopic stress relaxation and molecular-level chain exchange in triblock copolymer micelles has been explored using rheology and time-resolved small-angle neutron scattering (TR-SANS), marking the first measurements of chain exchange in concentrated triblock networks. It has long been assumed in models of transient or thermoreversible networks that the time scales for these two processes are equal. Experimentally, we find that stress relaxation occurs many orders-of-magnitude faster than chain exchange. This difference is quantitatively explained by modest dispersity in the core block that results in a slight asymmetry within any given nominally symmetric triblock. For stress relaxation to occur, only the shorter chain must pull out, while chain exchange is slowed due to the requirement of the eventual pullout of the longer block. The pullout time is extremely sensitive to the length of the core block. This mechanism is supported by measurements with an intentionally asymmetric triblock copolymer, which displays an even larger difference between the stress relaxation and chain exchange rates. These results establish a quantitative molecular-level picture of the chain dynamics associated with stress relaxation in triblock copolymer networks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Enhanced Stress Relaxation Behavior via Basal ⟨a⟩ Dislocation Activity in Zircaloy-4 Cladding

Herein this work evaluates the stress relaxation behavior of textured Zircaloy-4 cladding to understand how mechanical anisotropy influences pellet-cladding interactions. Uniaxial and biaxial stress relaxation tests are performed using full-tube axial tension and internal pressurization, respectively, aiming to achieve 0.25%, 1%, and 2% equivalent strains in the cladding samples at a temperature of 300°C. Internal pressure relaxation test results display enhanced stress relaxation compared to axial testing results, particularly for samples loaded beyond yield. Results of electron backscatter diffraction indicate increased deformation microstructure during loading and increased strain homogenization and recovery during relaxation for samples loaded via internal pressurization. Analysis indicates that the increased production and activity of basal ⟨a⟩ dislocations play a significant role in the enhanced relaxation measured in samples subjected to internal pressurization.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Design and Scoping Tests on Alloy 617 Using Notched Specimen Geometry to Validate Methods for Multiaxial Stress Relaxation

In FY 2022, a development effort was initiated at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) to examine the multiaxial stress-relaxation behavior and multiaxial stress-state effect on the creep-fatigue (CF) performance for Alloy 617 at elevated temperatures. This effort supported the development of the design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5. In this work, two types of the notch specimen geometries were designed. An inelastic constitutive model was used to investigate the stress triaxiality and elastic follow-up effects on the notch specimens under CF deformation in the finite element (FE) simulations. The numerical study demonstrated that the stress triaxiality and elastic follow-up caused by the notches both play significant roles in the stress-relaxation behavior. In addition, Alloy 617 CF experiments were designed, and the testing on the notch specimens is ongoing. CF test failure data will be generated on the specimens with notches under various conditions in FY 2023, and the results will be used to validate methods for accounting for the multiaxial stress relaxation effect in the design code.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Stress relaxation cracking susceptibility evaluation in 347H stainless steel welds

Abstract Stress relaxation cracking (SRC) has been reported as a dominant failure mechanism for 347H stainless steel welds at elevated service temperatures, occurring in either the heat-affected zone (HAZ) or fusion zone (FZ). In this study, SRC susceptibility of physically simulated HAZ and cross-welded E347-347H stainless steel welds was studied using a four-step accelerated SRC test with a thermomechanical physical simulator. The stress and temperature range studied represents weld-induced residual stress at 150–600 MPa and post-weld heat treatment temperatures between 800 and 1050 °C. For all temperature conditions, the cross-welded samples failed at a lower critical stress threshold than the simulated HAZ. A finite element model of a 50.8-mm-thick single-V groove weld was used to generate the residual stress maps induced by a 40-pass welding procedure, which in combination with the experimental threshold stress map predicted potential SRC failure locations. Postmortem microstructural evaluations were performed to identify contributing characteristics to SRC. It was found that HAZ samples exhibited a combination of creep void development, secondary cracks with intergranular fracture near grain boundary carbides, and eutectic phases. FZ samples showed brittle fracture with cracks propagating along straight, non-tortuous interdendritic grain boundaries.

42 ENGINEERING↗
DOE OSTI2022

Mechanical response and microstructure evolution from multiaxial stress relaxation in textured zircaloy nuclear cladding

Modern energy markets provide motivation for nuclear reactors to increase operational flexibility and load following capacity of existing reactor designs. The operational power changes result in fuel pellet expansion and contraction resulting in pellet-cladding mechanical interaction (PCMI) and high cladding stresses that are strongly related to stressed corrosion cracking (SCC) which can lead to fuel rod failure. This work aims to quantify the stress fields in cladding with a focus on multiaxial stress relaxation response from an imposed strain and the resulting microstructure changes in textured zircaloy claddings. Stress relaxation tests resulting in multiaxial stress fields are performed to measure the material response of Zircaloy-4 nuclear cladding. Multiple experiments using samples from the same piece of cladding are performed so samples with the same processing history may be removed at strategic points throughout mechanical testing for microstructure characterization. The microstructure evolution is analyzed with mechanical response to evaluate the static recovery impact on crystallographic texture and grain morphology. Experiments are performed at Idaho National Laboratory using an experimental device capable of applying internal pressure and independent axial load to commercial nuclear cladding at elevated temperatures with stress- or strain-controlled experimental capability. X-ray diffraction and electron backscatter diffraction are used for microstructure analysis. Rheological models are used to visualize the multiaxial stress-strain relationships and isolate elastic, plastic, and viscoplastic material properties for analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Identifying multiple synergistic factors on the susceptibility to stress relaxation cracking in variously heat-treated weldments

The 347H austenitic stainless steel has been widely used for pressure vessels and pipeline (PVP) applications due to its excellent creep and corrosion resistance, which fit ideally to the harsh conditions in petrochemical industries, fossil fuel or nuclear power plants, and modern energy storages. However, a failure mode has been commonly observed with cracks emerging at the heat affected zone (HAZ) of weldments during post-weld heat treatment (PWHT) or under intermediate to high temperature service conditions. This phenomenon is termed as Stress Relaxation Cracking (SRC) since the purpose of PWHT is to relieve the welding-induced residual stress fields, or as Stress Age Cracking (SAC) if failure happens during service. A leading literature explanation of this failure suggests that the residual stress relaxation and the precipitation dissolution and/or re-precipitation occur in the same temperature range, which can lead to locally high strains and thus to crack at the grain boundaries. Since in situ spatial measurements of residual stress fields, microstructural evolution, and failure processes are nearly infeasible, this work recourses to a micromechanical finite element framework that models the high temperature failure as the nucleation and growth of grain boundary cavities, whereas various parameters such as thermomechanical loading history and its evolution, the competition of grain-interior dislocation creep and grain-boundary diffusion in failure lifetime, and microstructural heterogeneities (such as the precipitate free zone near grain boundaries) can be quantitatively incorporated. It can be concluded from these microstructure-explicit simulations that an accurate knowledge of residual stress evolution and a carefully calibrated set of material constitutive parameters are the essential prerequisites for lifetime predictions. The understanding of individual governing factors also leads to a mechanistic interpretation of the observed SRC susceptibility C-curves. In conclusion, these results suggest that the criticality of residual stress evolution, but not the precipitation-induced local strains, be the leading factor for SRC.

347H stainless steel weldments↗
DOE OSTI2025

Modified 316H constitutive model updated with high temperature stress relaxation test data

This report describes the calibration of a new high temperature constitutive model for 316H stainless steel, suitable for use with the ASME Boiler & Pressure Vessel Section III, Division 5, Class A rules for design by inelastic analysis. The model retains the same mathematical form used by the reference model included in Nonmandatory Appendix Z of the Code, but refits the model to an expanded dataset including all the data used to fit the original model plus seven new stress relaxation tests. The addition of these high temperature stress relaxation tests improves the model's accuracy in predicting relaxation at temperatures greater than 700 ⁰C, without compromising the accuracy of the model versus the original calibration data.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Stress Relaxation Cracking in 347H Stainless Steel Arc Welds: Susceptibility Evaluation of Heat-Affected Zone

Stress relaxation cracking (SRC) is considered one of the major failure mechanisms for 347H stainless steel welds at elevated service temperatures or during post weld heat treatment (PWHT), especially within the heat-affected zone (HAZ). This work focuses on the characterization of SRC susceptibility within 347H physically simulated arc welded HAZ at elevated temperatures. A four-step SRC thermomechanical test in combination with finite element modeling (FEM) of the welding and testing processes is developed to establish a susceptibility map for HAZ. The test first runs a thermal cycle with three different peak temperatures (1335, 1275, and 1150 °C) to duplicate representative HAZ subzone microstructures, followed by time-to-failure examination under a variety of pre-stress (260–600 MPa) and pre-strain conditions (0.03–0.19) as a function of reheat temperatures between 750 and 1050 °C. With the aid of FEM, SRC susceptibility maps are generated to identify the threshold stress, plastic strain, and creep strain as a function of test temperature. It was found out that HAZ subzone with a lower peak temperature (1150 °C) appears to be slightly less susceptible to SRC than the other two subzones that experienced higher peak temperatures. Generally, time-to-fracture reduces with increasing initially applied stress and strain for all test temperatures. The pre-stress thresholds decrease from about 500 to 330 MPa as the testing temperature increases from 800 to 1050 °C, while the corresponding initial plastic strain thresholds reduces from 0.15 to 0.06. The SRC susceptibility was also evaluated through the Larson–Miller Parameter (LMP) analysis as a function of plastic strain, initial stress and starting stress upon reaching the testing temperature, respectively. The 1050 °C test with a high pre-applied strain (0.1) exhibits an extremely short time to failure (t = 3 s) that lies outside the general trend in LMP analysis. Additionally, it was identified that a plastic strain above 0.07 is identified to significantly reduce the bulk creep strain tolerance to fracture and therefore increases SRC susceptibility. Hardness measurement and fractography analysis indicated that the strain aging of niobium carbonitrides and other potential phases in conjunction with intergranular precipitates contributes to an increase in microhardness and increased intergranular cracking susceptibility.

14 SOLAR ENERGY↗
DOE OSTI2025

Predicting long-term stress relaxation on Alloy 709 using the crystal plasticity finite element method

This report summarizes the results of physics-based, crystal plasticity simulations for the long-term stress relaxation behavior of Alloy 709. The purpose of the study was to provide insight into five key questions related to long-term behavior in high temperatures materials which are difficult or impossible to answer experimentally: (1) is there a threshold stress for long-term relaxation? (2) is there strain threshold for relaxation damage, below which significant damage does not accumulate? (3) does damage continue to accumulate as the material relaxes or will damage accumulation plateau under some loading conditions? (4) does stress relaxation loading inevitably lead to failure? and (5) which, if any, engineering models for relaxation damage accumulation reasonably match the simulation results? The report summarizes the numerical simulations used to address these five questions and provides at least partial answers to each question.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Intermediate time sub-diffusion and stress relaxation in ring polymer melts

The slow dynamics of non-concatenated ring melts remains a frontier problem in polymer science with implications for many soft material environments including cellular biophysics. Here, in this work, we report large-scale simulations of model ring melts that analyze the monomer and center-of-mass (CM) mean square displacements (MSD) and stress relaxation function on intermediate time and length scales. The degree of dynamical slowing down is characterized by the maximally sub-diffusive fractional time scaling exponents. The data span an exceptionally wide range of ring degrees of polymerization and stiffnesses and are not successfully organized based on the classic measure linear chain entanglement, N/N e . Rather, we find that the crossover degree of polymerization, N D , based on ring macromolecular caging that successfully allows master curves to be constructed for the long-time CM self-diffusion constant also collapses these temporal dynamic scaling exponents. Different properties display different exponents and exhibit one or two regimes of linear variation with the logarithm of N D / N . A distinct crossover of the CM-MSD and stress relaxation exponents emerges at sufficiently large N or stiffness that is not found for the monomer MSD, indicating a novel form of dynamic decoupling. This crossover aligns with the predicted critical degree of polymerization for transitioning from a weak to strong caging regime, indicative of activated transport. The latter may reflect the emergence of an intermolecular collective contribution to stress in analogy with dense soft colloidal matter. Suggestions are made for future theoretical work to address the rich patterns of behavior discovered.

Anomalous diffusion↗
DOE OSTI2024

Stress Relaxation Cracking of Alloys at Temperatures Higher Than 540°C

Type 347H stainless steel (347H SS), used in commercial concentrating solar power (CSP) thermal energy storage to store solar-salt at a temperature of 565°C, has been reported in the literature to be susceptible to stress-relaxation cracking (SRC). The welded heat-affected zone (HAZ) and fusion zone (FZ) of 347H SS, particularly in thick sections, are known to be susceptible to failure during post-weld heat treatment (reheat cracking). SRC could also occur after months or years under an elevated-temperature service environment. Two conditions must be present for failure to occur in the HAZ and/or FZ: 1) a modified or sensitized microstructure and 2) sufficiently high tensile residual stresses present at the elevated service temperature. The overarching goal of this project is to recommend SRC mitigation protocols to avoid susceptibility to fail through SRC at temperatures relevant for CSP. Post weld heat treatment conditions and alternative alloys are investigated as potential mitigation solutions to SRC. We used Gleeble thermomechanical simulation tests and finite element (FE) models to understand the susceptibility of 347H SS to SRC as a function of temperature, stress, and microstructure. We started with a literature review of weldability issues with 347H SS and techniques to mitigate SRC in 347H SS weldments. Next, we used Gleeble experiments to determine reheat cracking susceptibility in the simulated HAZ of 347SS weldments and an alternative alloy, 316L SS (NUCL 167 SPH) with boron added. We also performed Gleeble experiments to compare the reheat cracking susceptibility of 347H cross welded with two different fillers: E347, which is used in some commercial CSP TES tanks, and E16.8.2. We validated the experimental results with FE models of the residual stresses. We found that although the 316L (NUCL 167 SPH) is less susceptible to reheat cracking, it is slightly weaker than 347H and ASME BP&V codes limit its use to a service condition of 565°C. We also found that welds using E16.8.2 as the weld filler are less susceptible to failure than those using E347, likely due to the higher creep ductility of E16.8.2, and that it may be used as an alternative filler for repair welding of 347H welds or as the primary choice of filler for newly developed weld joints. We also found that post weld heat treatment could be a viable solution for mitigating stress in E347-347H SS thick, constrained welds, like those found in CSP tanks, and propose several options for mitigating SRC in existing and future TES tanks.

14 SOLAR ENERGY↗
DOE OSTI2023

Discrete Measurements of the Least Horizontal Principal Stress from Core Data: An Application of Viscoelastic Stress Relaxation

Summary The emerging Paradox Oil Play in southeastern Utah is among the most significant unconventional plays in the western USA. The mean total undiscovered oil resources within just the Pennsylvanian Cane Creek interval of the Paradox Basin are believed to exceed 215 million barrels. However, to date, less than 5% (~9 million barrels) of the total Cane Creek resource has been produced from fewer than 40 wells, and only approximately one-half of those are horizontal wells. More than 95% of production is from the central Cane Creek Unit (CCU). Natural fractures are a key feature of many production wells, but stimulation by induced hydraulic fractures is not consistently successful. We hypothesize that more effective production in this play will rely on better fundamental characterization, especially on better quantification of the state of stress. Approximately 110 ft of core, well logs, and a diagnostic fracture injection test (DFIT) were acquired from the State 16-2 well within the CCU. With these data, we applied two methods to constrain and clarify the state of stress. The first technique, the Simpson’s coefficient method, provides lower bounds on the two horizontal principal stresses and relies on only limited data. Alternatively, the viscoelastic stress relaxation (VSR) method is used to estimate the least horizontal principal stress, building on observations that principal stresses become more isotropic as the viscous behavior of a rock is more pronounced. Results of these two methods support the hypothesis that the state of stress in the CCU of the Paradox Basin is nearly lithostatic and isotropic. Other factors consistent with this hypothesis include high formation pore pressure, which tends to reduce the possible stress states by changing the frictional failure equilibrium; lack of induced fractures in the core, which should be present in the case of stress anisotropy; and interbedded halite layers, which given their high degree of ductility, probably lead to greater VSR for the entire sedimentary package.

Energy & Fuels↗
DOE OSTI2023

Factors Influencing Propensity for Stress Relaxation Cracking in Inconel® Alloy 740H® and Practical Guidance for Applications

Inconel® alloy 740H® (UNS N07740) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. In recent years, advanced energy systems such as supercritical CO2 power cycles have utilized alloy 740H in large demonstration projects driven by the requirement for higher fluid temperatures and pressures. Stress relaxation cracking (SRxC) following post-weld heat-treatment (PWHT), also known as strain age cracking (SAC), has been identified in a limited number of weldments during these industrial builds resulting in focused research to further clarify factors influencing this cracking tendency. This paper will summarize some of the findings from shop and field fabrication leading to successful welds and characteristics of observed SRxC. Laboratory experiments supported by microstructural characterization will be presented to highlight the importance of variables such as strain, material starting condition, and PWHT temperatures. Finally, the results will be summarized within the context of practical guidance for industry to successfully weld the material in boiler, heat exchanger, and piping applications.

14 SOLAR ENERGY↗