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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 OSTI2025

In Situ Measurement of Stress Corrosion Crack Tip Properties During Environmentally Induced Cracking in Stainless Steel 304L

The influence of the external cathodic area, stress intensity, and electrochemical polarization level on the resultant crack growth rate and crack tip pH and potential was studied for stainless steel 304L in a sodium chloride environment. Before testing, the validity of in situ crack tip property measurements using microprobes and drilled holes was supported through modeling efforts and confirmed with experimental observations. Here, it was found that increasing the R-ratio during corrosion fatigue increased the crack growth rate and decreased the measured crack tip pH of the 304L sample. Decreasing the electrochemical potential (i.e., cathodic polarization) of the bulk sample increased the crack tip pH and stopped measured crack extension under constant K conditions. Conversely, increasing the potential of the bulk sample decreased the crack tip pH and induced cracking under constant K conditions. Decreasing the cathodic area external to the crack increased the measured pH at the crack tip and decreased the crack growth rate under fatigue conditions. For the given configuration, environment, and alloy studied, fatigue crack growth is not sustained by cathodic reactions solely occurring in the crack wake and notch. These results have implications for the ability to predict atmospheric crack growth rates from laboratory, full immersion experiments.

corrosion fatigue↗
DOE OSTI2021

Direct observations and characterization of crack closure during microstructurally small fatigue crack growth via in-situ high-energy X-ray characterization

This study provides direct observation of the crack closure mechanism of a naturally occurring, tortuous, 3D microstructurally small fatigue crack (SFC) in additively manufactured Inconel 718. In-situ non-destructive characterization is performed using high-energy X-ray diffraction techniques to capture the evolution of the 3D microstructure and micromechanical response in the vicinity of the crack front. Based on the stress state of twelve grains analyzed at the crack tip, the crack closure events of the SFC front was found to be spatially heterogeneous with respect to loading progression governed by the local stress state of the grains (specifically the stress reversal from compression to tension). From this analysis, three grains that displayed different degrees of crack closure were further investigated, based on the orientation of the crack relative to the grains and the associated modality of crack growth. The stress normal to the crack plane and the associated degree of Mode I crack behavior were correlated with events of the crack opening earlier during the loading cycle. This was further corroborated by diffraction spot spreading analysis that quantified the crystallographic lattice distortion caused by the opening crack. Additionally, the detailed characterization of the opening behavior of the grains located at the crack tip and their associated states of stress elucidates the mechanism governing crack closure and will inform future modeling efforts of this phenomenon.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Inversion-based correction of Double-Torsion (DT) subcritical crack growth tests for crack profile geometry

Because of its simplicity and the ability to produce a stable, slow-propagating crack, the Double-Torsion (DT) method has been used widely for investigating the critical and subcritical propagation of a slow-propagating tensile (mode-I) crack. However, to determine the complex relationship between the crack velocity $\mathcal{v_c}$ vs. the strain energy release rate $\mathscr{G}$ (or the stress intensity factor K) from laboratory measurements, several corrections must be made to account for the impact of sample and crack geometry. Particularly, DT test typically produces a crack with a curved edge profile instead of a straight line, causing the local $\mathcal{v_c}$ and $\mathscr{G}$ vary along the crack front. The experimentally measured $\mathcal{v_c}$ and $\mathscr{G}$ data merely reflect collective, averaged behavior of the crack. This makes inversion for the intrinsic, “true” crack growth kinetics necessary, based upon the knowledge of the crack geometry. Simple and effective correction methods have been proposed and validated for the slow, chemical-reaction-controlled part (Region I) of the $\mathcal{v_c}$-$\mathscr{G}$ curve. However, reliable methods for the highly nonlinear, transport-dominated part (Region II) and its sudden transition to the dynamic propagation part (Region III) are still lacking. Here we propose a method for determining the intrinsic $\mathcal{v_c}$-$\mathscr{G}$ relationship across all three Regions based upon DT test data, using a simple model function and its numerical inversion. The performance of this approach is examined and demonstrated using both synthetic and laboratory data for subcritical crack growth in soda lime glass.

42 ENGINEERING↗
DOE OSTI2025

Determination of Constraint-Independent Crack Tip Opening Angle for Stable Crack Growth in High-Strength Ductile Steels

The crack tip opening angle (CTOA) is one of fracture toughness parameters that has been used for decades in describing large stable crack growth in thin-walled aerospace structures under the low-constraint conditions. Recently, the pipeline industry has developed a growing interest in using the CTOA parameter to serve as the minimum required fracture toughness to arrest dynamic crack propagation in modern gas transmission pipelines made of high-strength ductile steel. To meet this industrial need, the CTOA test standard ASTM E3039 was therefore developed for measuring the constant critical CTOA. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen with a shallow crack for standard CTOA testing, but its CTOA may depend on the low constraint condition of the DWTT specimen at the crack tip. Verifying the constraint independence of the DWTT-measured CTOA thus becomes indispensable for applying CTOA toughness to the running fracture control in the pipeline design. For this purpose, the present paper evaluates critical CTOA values in a set of fracture toughness tests on single-edge notched bend (SENB) specimens with shallow and deep cracks, based on four CTOA estimation models. Among these, the Ln(P)-LLD linear fit model is similar to that recommended by ASTM E3039 for CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel were considered in the CTOA evaluation. The results showed that the four CTOA models were able to determine a constraint independent CTOA value for stable crack growth in the SENB specimens. As a result, a single, reliable, constant CTOA value could be determined regardless of the specimen geometry or the crack-tip constraint conditions. Therefore, the CTOA measured using ASTM E3039 is constraint-independent and transferable to use in cases of actual cracks propagating in gas transmission pipelines.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanism of chlorine-induced stress corrosion cracking of two 304 SS heats in simulated marine environment through in situ X-ray tomography and diffraction: Role of deformation induced martensite and crack branching

In this work, In-situ synchrotron x-ray tomography and diffraction experiments were conducted on two heats of 304SS undergoing chlorine-induced stress-corrosion-cracking (CISCC) in a simulated marine environment. The role of deformation induced martensite on CISCC was investigated through diffraction analysis where no significant amount of martensite was found to form during CISCC, indicating that it may not play a significant role in affecting the process. Tomography combined with stress-intensity analysis revealed the influence of stress-intensity on branching types with single crack growth, micro-branching, and macro-branching. Post experimental electron microscopy characterization revealed the presence of FeCl 2 , CrCl 2 , and NiCl 2 ·6H 2 O compounds at the crack, which infers a dissolution mechanism during the experiment. A dissolution mechanism highlighting the synergy between stress and corrosion was proposed to explain chlorine-induced stress-corrosion-cracking and crack branching.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The physics of desiccation cracks 2: Modeling and prediction of the crack patterns

Here, this paper extends the experimental results of our companion paper by modeling and predicting the onset and pattern formation of desiccation cracks in geomaterials (Ruoyu et al., 2023). Thin-layer silt samples in controlled atmospheric conditions were tested to obtain the surface strain maps with the digital image correlation (DIC) method during dehydration. Support experiments, including consolidation and displacement-controlled triaxial tests, were conducted for the properties of geomaterials. These experimental results were used to validate a viscoplastic theoretical model by comparing cracks and singularities locations that distribute following the Cnoidal wave pattern. A critical value exists in the viscoplastic model that determines the number of singularities, which accurately predicts the number of cracks in the experiment. The critical values contain two crucial parameters: rate sensitivity and λ. Rate sensitivity describes the rate-dependent stress–strain relation, while λ shows the ability of pore pressure redistribution under the external mechanical loading rate. These results provide a new view to analyze the desiccation cracks considering the rate-dependent viscoplasticity.

42 ENGINEERING↗
DOE OSTI2024

Summary of Alloy 617 and Alloy 709 Elevated Temperature Crack Growth Test Results from the Planned FY24 Crack Growth Test Activities

This report covers the results from crack growth rate testing performed at Idaho National Laboratory in the fiscal year 2024. It includes two creep crack growth rate tests and two creep-fatigue crack growth rate tests. Results are shown for each of these tests, included crack growth measured during the test using direct current potential drop, and measurements based off of the fracture surface. Load line displacement, as well as load, were also collected during the tests. Detailed analysis of the results will continue into the next fiscal year, however, a number of potential improvements to the equipment and testing procedures were identified that will increase testing reliability and throughput, as well as decrease complications with the analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗