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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 OSTI2021

Alternative Damage Tolerant Materials for Wind Turbine Blades: An Overview

Current wind turbine blade materials may not be damage tolerant to the extent necessary to optimize the Levelized Cost of Energy (LCOE) of wind energy plants. Traditionally, wind turbine blades have been designed using a safe-life approach, but advances in inspection techniques and structural health monitoring solutions give rise to the opportunity to design wind turbine blades using a damage tolerant approach. Materials selection is a key element of da mage tolerant design, so the extent of the damage tolerance of alternative materials has been analyzed through a literature review and discussions with industry leaders. Fabrics and resin selection significantly affect the damage tolerance of composites. Changes to fabric architecture may include through-the-thickness (TTT) fibers, stretch-broken carbon fiber (SBCF) composites, and aligned discontinuous fiber reinforced composites (ADFRCs). Previous research has demonstrated that using TTT fibers in creases damage tolerance, but additional research is necessary to demonstrate the effectiveness of SBCFs and ADFRCs in mitigating damage. Several studies have demonstrated increased damage tolerance when toughened resin systems are used. In addition to toughened resin systems, thermoplastics have been shown to be tougher than thermosets. However, thermosets have been traditionally preferred in wind turbine blade manufacturing due to ease of manufacturing. Thermoplastic resin system s have been developed that can be used with conventional manufacturing methods but have yet to be studied for its damage tolerant capabilities. Furthermore, cost and stress analyses on where to effectively implement TTT fibers, SBCF composites, ADFRCs, and toughened resin systems must be executed prior to incorporating new materials into wind turbine blade manufacturing.

17 WIND ENERGY↗
DOE OSTI2024

Multi-functional cementitious materials with ultra-high damage tolerance and self-sensing ability

Cementitious materials having high damage tolerance and self-sensing ability are described herein. These materials may replace conventional concrete to serve as a major material component for infrastructure systems with greatly improved resistance to cracking, reinforcement corrosion, and other common deterioration mechanisms under service conditions, and prevents fracture failure under extreme events. These materials can also be used for the repair, retrofitting or rehabilitation of existing concrete structures or infrastructure systems. Furthermore, these materials may offer capacity for distributed and direct sensing of cracking, straining and deterioration with spatially continuous resolution wherever the material is located, without relying on installation of sensors. The present invention relates to multifunctional cementitious structural or infrastructure materials that integrate self-sensing with damage tolerance for improving safety, extending service life, and health monitoring of structures, components, and infrastructure systems.

Li, Mo↗
DOE OSTI2024

Enhanced Radiation Damage Tolerance of Amorphous Interphase and Grain Boundary Complexions in Cu-Ta

Amorphous interfacial complexions are particularly resistant to radiation damage and have been primarily studied in alloys with good glass-forming ability, yet recent reports suggest that these features can form even in immiscible alloys such as Cu-Ta under irradiation. In this work, the mechanisms of damage production and annihilation due to primary knock-on atom collisions are investigated for amorphous interphase and grain boundaries in a Cu-Ta alloy using atomistic simulations. Amorphous complexions, in particular amorphous interphase complexions that separate Cu and Ta grains, result in less residual defect damage than their ordered counterparts. Stemming from the nanophase chemical separation in this alloy, the amorphous complexions exhibit a highly heterogeneous distribution of atomic excess volume, as compared to a good glass former like Cu-Zr. Complexion thickness, a tunable structural descriptor, plays a vital role in damage resistance. Thicker interfacial films are more damage-tolerant because they alter the defect production rate due to differences in intrinsic displacement threshold energies during the collision cascade. Overall, the findings of this work highlight the importance of interfacial engineering in enhancing the properties of materials operating in radiation-prone environments and the promise of amorphous complexions as particularly radiation damage-tolerant microstructural features.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Improving the damage tolerance of Si 3 N 4 by forming laminate composites with refractory metals

The objective of this research was to demonstrate that the damage tolerance of Si 3 N 4 could be significantly improved by forming laminate composites with refractory metals, providing materials that undergo graceful failure, rather than the fast-fracture mechanism exhibited by monolithic Si 3 N 4 . A damage tolerant Si 3 N 4 could be used as a ring material in an all-ceramic bearing, decreasing the chance for catastrophic failure if the ring is stressed in tension during operation. The technical approach formed a laminate composite material using alternating Si 3 N 4 -metallic layers, with both outer layers being Si 3 N 4 to take advantage of its greater wear resistance, chemical stability, and thermal stability. The metallic layers are designed to arrest any cracks in the outer layers, thus producing a toughened Si 3 N 4 and avoiding the catastrophic failure behavior exhibited by monolithic ceramics. The laminate composites were fabricated using a combination of tape-casting Si 3 N 4 and metals from slurries, as well as metal foils, followed by hot pressing at 1500°C. The metallic materials employed were chromium, titanium, and tantalum. Analysis confirmed that the interfaces were well formed, and the laminates with chromium and titanium formed intermetallic compounds more readily than the composites with tantalum. The Si 3 N 4 -Ta laminates demonstrated crack deflection and bridging behavior during failure and flexural strength of 800–900 MPa. The hardness and elastic modulus of Si 3 N 4 -Ta laminates measured by nanoindentation were similar to those reported in literature. The hardness across the interface of the Si 3 N 4 -Ta composite varied according to the composition of the interface, which displayed a profile indicative of a diffusion bond.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Improved damage tolerance of SiC-based nuclear fuel cladding with novel multi-layered SiC coating design at 1200 °C

Continuous SiC fibre reinforced SiC matrix composites (SiC f -SiC m ) with monolithic SiC outer coatings are considered as a damage-tolerant cladding design for loss of coolant accident (LOCA) conditions in light water reactors. However, monolithic SiC coatings are brittle and prone to catastrophic failure. In this study, a SiC f -SiC m cladding with a novel multi-layer SiC outer coating (11 sub-layers, ∼260 µm in total thickness) was investigated under C-ring compression at room temperature and 1200 °C in argon environment. Real-time synchrotron X-ray computed tomography (XCT) was employed to capture crack initiation and propagation processes. Compared to conventional monolithic SiC outer coatings, the multi-layer coating structure facilitated crack deflection and bifurcation enhancing its damage tolerance at both temperatures. Despite pre-existing surface cracks, claddings exhibited stable mechanical-performance at both temperatures. These initial cracks did not critically affect the failure processes as they were not aligned with the maximum stress direction. Furthermore, the microstructure, distribution of residual stresses, and local properties of individual components in the material were thoroughly characterized, and compared with open literature on conventional claddings with monolithic outer coatings. These results provide new insights into the failure mechanisms of multi-layer SiC coatings and offer guidance for the future design of accident-tolerant nuclear fuel claddings.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Local structural ordering determines the mechanical damage tolerance of amorphous grain boundary complexions

Amorphous grain boundary complexions act as toughening features within a microstructure because they can absorb dislocations more efficiently than traditional grain boundaries. This toughening effect should be a strong function of the local internal structure of the complexion, which has recently been shown to be determined by grain boundary crystallography. To test this hypothesis, molecular dynamics are used here to simulate dislocation absorption and damage nucleation for complexions with different distributions of structural short-range order. Here, the complexion with a more disordered structure away from the dislocation absorption site is actually found to better resist crack nucleation, as damage tolerance requires delocalized deformation and the operation of shear-transformation zones through the complexion thickness. The more damage tolerant complexion accommodates plastic strain efficiently within the entire complexion, providing the key mechanistic insight that local patterning and asymmetry of structural short-range order controls the toughening effect of amorphous complexions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Damage tolerance in the graphite cores of UK power reactors and implications for new build

The United Kingdom has been operating graphite-moderated gas-cooled commercial nuclear power reactors for more than 60 years. Both Generation I Magnox reactors and Generation II Advanced Gas-cooled Reactors have operated beyond their nominal design lifetimes and the safety cases for continued operation have had to address the issue of damage tolerance of the graphite cores. This review describes the designs of the reactors and the methodologies employed for their assessment. Emerging issues arising from extended operation and ageing of the cores are discussed together with the evolution of assessment methodologies to address predicted and observed damage. The UK nuclear regulator perspective is summarised and some conclusions are drawn on the implications for new build.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Multiscale mechanical design of the lightweight, stiff, and damage-tolerant cuttlebone: A computational study

Cuttlebone, the endoskeleton of cuttlefish, offers an intriguing biological structural model for designing low-density cellular ceramics with high stiffness and damage tolerance. Cuttlebone is highly porous (porosity ~93%) and lightweight (density less than 20% of seawater), constructed mainly by brittle aragonite (95 wt%), but capable of sustaining hydrostatic water pressures over 20 atmospheres and exhibits energy absorption capability under compression comparable to many metallic foams (~4.4 kJ/kg). Here, in this work, we computationally investigate how such remarkable mechanical efficiency is enabled by the multiscale structure of cuttlebone. Using the common cuttlefish, Sepia Officinalis, as a model system, we first conducted high-resolution synchrotron micro-computed tomography (µ-CT) and quantified the cuttlebone's multiscale geometry, including the 3D asymmetric shape of individual walls, the wall assembly patterns, and the long-range structural gradient of walls across the entire cuttlebone (ca. 38 chambers). The acquired 3D structural information enables systematic finite-element simulations, which further reveal the multiscale mechanical design of cuttlebone: at the wall level, wall asymmetry provides optimized energy absorption while maintaining high structural stiffness; at the chamber level, variation of walls (number, pattern, and waviness amplitude) contributes to progressive damage; at the entire skeletal level, the gradient of chamber heights tailors the local mechanical anisotropy of the cuttlebone for reduced stress concentration. Our results provide integrated insights into understanding the cuttlebone's multiscale mechanical design and provide useful knowledge for the designs of lightweight cellular ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Doping Metallic Grain Boundaries to Control Atomic Structure and Damage Tolerance

Grain boundaries often act as sites for crack and void nucleation during plastic deformation of metallic materials. While it is known that grain boundary character and structure can greatly influence this damage nucleation process, the current level of control over such details is limited. The objective of this project was to obtain a fundamental understanding of how metallic grain boundary structure can be controlled through intelligent doping, with the idea of inducing planned amorphous grain boundary phases or complexions. The effect of amorphous complexion structure on dislocation accommodation mechanisms was studied, to improve the field’s understanding of damage nucleation at a promising type of interface. Different microstructural descriptors were studied, as grain boundaries can have large variations and complexity of local structure, and influence the mechanical damage resistance of these features was tested. Nanocrystalline systems that contain amorphous grain boundary complexions were prioritized, as these have more extreme variations in interfacial structure and damage tolerance, with an emphasis on isolating the importance of complexion population (type, thickness, etc.), network topology, local structure, and local chemistry. This research used a combination of computational, experimental, and characterization techniques to isolate and understand the importance of nanoscale grain boundary structure and interfacial chemistry. Amorphous grain boundary complexions were found to clearly increase a material’s resistance to mechanical damage, with the local distribution of structural short-range order within the complexions found to be an important descriptor for damage and the proposed focus of future work in this area.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Damage Tolerance Assessment of Laser Clad Repairs of Coarse Grain Ti-6Al-4V

Background: Laser cladding offers a promising approach to repairing aviation components, with the ability to restore the geometric shape and the static and fatigue strength. Objective: The damage tolerance of a coarse grain Ti-6Al-4 V material is assessed via three sets of samples: (i) baseline, (ii) laser clad repaired, and (iii) laser cladding followed by heat treatment. Method: The specimens were subjected to fatigue loading using a marker band technique, in which cracks initiated from pre-defined laser slots and the small crack growth rates were measured by quantitative fractography. Additional characterization was performed on these samples, including hardness measurements, microstructure analysis, and multimodal residual stress analyses. Results: The region of the specimen undergoing laser cladding exhibited higher hardness values and a compressive residual stress, based on the slitting method. The samples subjected to heat treatment after cladding displayed negligible differences in grain size and minimal residual stress relaxation. Conclusions: The results demonstrated significant variability, with data demonstrating that cracks in the laser clad region (exhibiting the largest compressive residual stress) grew faster than cracks in the substrate region of the sample or in the baseline cases. Finally, these counterintuitive results are rationalized with additional analyses from synchrotron-based energy dispersive X-ray diffraction and high energy X-ray diffraction, demonstrating significant spatial variability in the residual elastic strains in the millimeter-sized prior β grains within the material.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Doping Metallic Grain Boundaries to Control Atomic Structure and Damage Tolerance (Final Report)

The interfaces between crystals, known as grain boundaries, often act as sites for crack and void nucleation during plastic deformation of metallic materials. While it is known that interfacial character and structural state can greatly influence this damage nucleation process, the current level of control over such details is extremely limited. The objective of this project was to obtain a fundamental understanding of how metallic grain boundary structure can be controlled through intelligent doping, with the idea of inducing planned grain boundary phases or complexions. The effect of complexion structure on dislocation accommodation mechanisms was studied, to improve the field’s understanding of damage nucleation at interfaces. While mechanical damage was the primary focus, the project showed that amorphous complexions can also improve a material’s resistance to radiation damage, providing a single materials design concept that can address multiple important technological areas. This research used a combination of computational, experimental, and characterization techniques to isolate and understand the importance of nanoscale grain boundary structure and interfacial chemistry. The fundamental insights provided by this project enable the creation of advanced engineering metals with improved damage tolerance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Evaluating the Lightning Strike Damage Tolerance for CFRP Composite Laminates Containing Conductive Nanofillers

Conductive nanofillers, such as carbon nanotube, graphene nanoplatelets, and carbon black particles (with diameters in nanometers) have been shown to enhance the electrical conductivity of fiber reinforced polymer matrix composites in many existing studies. The motivation is primarily for lightning strike protection, electromagnetic interference shielding, de-icing, and the manufacturing of lightweight electronic components. Here, we evaluate the lightning strike damage tolerance of carbon fiber reinforced polymer (CFRP) matrix composite laminates containing conductive nanofillers with varying weight fractions, including carbon black (CB), carbon nanotubes (CNT), and a mix of CB and CNT, through simulated lightning strike tests, followed by both non-destructive ultrasonic inspection and destructive sectioning to characterize the damage inflicted by the simulated lightning strike. Three-point flexural tests are performed to evaluate the residual strength retained by all CFRP specimens. Results show that lightning strike damage experienced varying levels of reduction for CFRP composite specimens containing conductive fillers in comparison to the baseline specimen without fillers. Notably, the delamination only penetrated to the interface between the 1st and 2nd layer for the specimen with 0.25 wt.% CNT in comparison to the baseline CFRP specimen for which the delamination penetrated to the interface between the 5th and 6th layer. Moreover, the retention of the flexural modulus increased from 26.5% to a maximum of 95.0% for the specimen with 0.25 wt.% hybrid CB and CNT. Yet, we show that using our chosen conductive fillers cannot fully eliminate lightning strike damage. Additionally, adding conductive fillers could compromise the flexural properties. We provide discussions on future recommendations on using conductive fillers for the lightning strike protection of CFRP composites.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fibrous anisotropy and mineral gradients within the radula stylus of chiton: Controlled stiffness and damage tolerance in a flexible biological composite

Over hundreds of millions of years, organisms have evolved architected structures via precise control over hierarchically assembled components, including the integration of dissimilar materials. One such example is found in the radula system of chitons, intertidal mollusks that feed on algae growing on the rock. Their radula consists of multiple rows of ultrahard teeth, each integrated with a foldable belt-like substrate via a stiff, yet flexible stylus, which is essential for efficient rasping during the feeding process. Here, we investigate the nano and micro-scale components and architectures as well as regional mechanical properties of the stylus, and their subsequent role during the rasping of Cryptochiton stelleri. Three important factors were determined to contribute to the regio-specific stiffness of the stylus: the presence of mineral components, highly oriented chitinous fibers, and a chemically cross-linked protein matrix. All these factors are varied throughout the stylus. There is a high mineral content on the trailing edge close to the tooth and a cross-linked matrix on the leading edge, both with orientational specific oriented chitin fibers that provide force transduction to the tooth. Conversely, there is a significant lack of mineral or cross-linked matrix in the proximal end as well as a low degree of fiber orientation, resulting in a flexible region that can accommodate torsion and flexure during rasping. Understanding the graded composite structure of the stylus and applying this unique design to various engineering fields such as soft robotics, biotechnology, and the medical industry, can inspire the production of high-performance materials.

Lee, Jung-Eun↗