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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 OSTI2023

Evaluation of the ring tension test (RTT) for robust determination of material strengths

The ring tension test (RTT) is an experimental method for determining mechanical behavior in a material’s circumferential or hoop direction. It is a crucial test for testing anisotropic materials with tube geometry, such as nuclear fuel cladding or irradiated pipes. Several RTT configurations exist, each with their own advantages and disadvantages. However, this test is significantly more complex than traditional tensile testing and can be especially sensitive to small differences and inconsistencies in the test setup and geometry, ultimately affecting the derived mechanical properties. Previous research has focused on method development, and little work has been done on understanding the subtle differences between an ideal test and experiments, specifically when the tests are performed on highly irradiated materials in hot cells. In this work, a finite element-based investigation of the RTT is conducted to fill this gap. The two most used test configurations are investigated, comparing their ability to determine accurate material strengths through plastic deformation. Several non-ideal conditions and uncontrollable effects which are likely to occur during experimental testing such as machining tolerances, variations of specimen geometry from nominal dimensions, rotation of specimens and fixturing, and other test setup discrepancies are studied. The sensitivity of measured strengths to these conditions is presented. A mechanics-based approach to describing and correcting raw data to determine actual strengths is also included for one of the configurations, resulting in a robust correction method with highly accurate material strength measurements. Finally, based on these analyses, the hemicylindrical mandrel configuration is recommended with a gauge region oriented at a 45° angle.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Design of a Three-Layer Impactor for Material Strength Measurements at Multi-Megabar Pressures

Off-Hugoniot loading methods for dynamic compression have been a topic of interest for many years as a means of accessing high pressures without melting a material. Simulations and an initial test experiment of a three-layer gas-gun impactor suitable for use in measuring dynamic material strength at multi-megabar pressures are described. As shown through ARES hydrocode simulations, an impactor consisting of a low-, medium-, and high-impedance material, such as TPX, Al, and Ta or Pt, can produce a quasi-isentropic loading path up to 4.6 Mbar pressure with a low homologous temperature (T/T melt = 0.1–0.25). These impactors can also be tailored to create a pressure drive suitable for a Lagrangian sound speed experiment. Simulated in-situ velocities were analyzed to determine the change in calculated strength due to non-uniformity in the impactor, which provides a measure of error sensitivity. An initial test of a three-layer projectile onto a flat target at 4.4 km/s impact velocity is reported. Finally, while the impactor incurred some delamination during firing, the measured sample/window interface velocity generally agrees with the simulated peak velocity and subsequent release, indicating the feasibility of this approach for measuring material strength.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Parallel Implicit Hydrodynamics with Material Strength for High Explosive Burn Calculations

High explosives are almost always evolving in some form of metal containment vessel. This fact requires that a materials model for the evolution of the metal containment vessel be part of any simulation of the HE. Since the actual form of the strength model to be used is an open question, we incorporate the material strength properties in a relatively agnostic fashion, which will accommodate many strength models. The only restriction is that the stress components be a function of density, specific internal energy and velocities. In addition, the timescales and rates of the chemical reactions in the HE vary between thousands of seconds and nanoseconds. A hydrodynamics capable of operating in anticipation of the eventual violent release of energy via these chemical reactions is a necessity. The central issue in creating a hydrodynamics capable of spanning these timescales is to forgo the use of a Courant time step control necessary in an explicit hydrodynamics. The Courant time-step arises because of characteristic velocities associated with the material, such as the sound speed or, in materials with strength, characteristic longitudinal and transverse speeds associated with compression and shear. The method used to circumvent the need for a Courant time-step limit is to develop an implicit calculation of the advanced particle pressure and shear modulus derived from the conservation laws of mass, momentum and specific internal energy. This process creates the implicit hydrodynamics needed for the HE calculations of interest to this study.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Breaking Boundaries: Deformation Processing Techniques for the Next Generation of Lightweight and High-Strength Materials

This chapter emphasizes the importance of solid phase processing (SPP) techniques in developing advanced materials for lightweight and high-strength applications. SPP methods like friction stir welding, and shear-assisted processing can create new microstructures and process materials in novel ways. SPP can enhance mechanical performance via various strengthening mechanisms like solid solution supersaturation, Hall-Petch and Orowan effects, and misorientation angle grain boundaries. The potential for in situ alloying or joining of components with near-net shape and low energy inputs, even for immiscible systems with high enthalpies of mixing, is also discussed. The chapter explores the concept of metastability through microstructural manipulation and the role of advanced characterization for atomistic understanding. The formation of metastable grain, shear-driven chemical mixing, and transformation pathways are also discussed. Finally, the emerging trends for SPP and the challenges that need to be addressed before realizing the full potential of these techniques are presented.

Lastovich, Michael↗
DOE OSTI2025

Modeling the evolution of slip localization: Realization of link to material strength

Slip localization formation is the chief mechanism underlying the deformation of almost all metals, from pure elements to high-performance superalloys. The intensity of individual slip localizations is often related to the ultimate strain level for failure but not to the strength of the metal. Here we show that across 15 distinct metals, the intensity of slip in individual slip localizations and slip localization spacings are strongly related to material yield strength. Using a three-dimensional crystal plasticity-based micromechanical model that explicitly simulates the growth of discrete slip localizations, we reveal that the stronger the metal, the faster and earlier slip localizations intensify. The relationship is attributed to the formation of a zone that surrounds the slip localization where the driving force for slip is absent. We find that the zone size is controlled by the strength of the neighboring crystal. Consequently, as strength increases, slip becomes increasingly preferred within the slip localization itself and formation of other slip localizations becomes more likely further away.

36 MATERIALS SCIENCE↗
DOE OSTI2024

SMATool: Strength of materials analysis toolkit

The study of the strength of materials is a cornerstone in material science and engineering, playing a critical role in shaping the progress and application of materials in diverse industrial sectors. The strength of a material is meticulously examined to understand the behavior of the material under different stress conditions and environments, thereby guiding material selection and structural design. Herein, we introduce the SMATool, a computational toolkit for the efficient calculation and analysis of material strength at both zero and finite temperatures for 3D, 2D, 1D, and tubular 2D-based nanostructures and nanotubes, as well as 1D nanoribbons. The toolkit is capable of calculating tensile, shear, ultimate, yield, and indentation (Vickers' hardness) strengths in various dimensions, as well as the energy storage capacity. We conducted several calculations both at zero and finite temperatures to validate the accuracy and reliability of the developed software. Here, the results show that the SMATool package provides accurate predictions that align with existing data on material strength. SMATool integrates seamlessly with widely used electronic structure codes like VASP and Quantum Espresso, providing a user-friendly interface catering to academic researchers and industry professionals.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A phase-field model for hydraulic fracture nucleation and propagation in porous media

Many geo-engineering applications, for example, enhanced geothermal systems, rely on hydraulic fracturing to enhance the permeability of natural formations and allow for sufficient fluid circulation. Over the past few decades, the phase-field method has grown in popularity as a valid approach to modeling hydraulic fracturing because of the ease of handling complex fracture propagation geometries. However, existing phase-field methods cannot appropriately capture nucleation of hydraulic fractures because their formulations are solely energy-based and do not explicitly take into account the strength of the material. Thus, in this work, we propose a novel phase-field formulation for hydraulic fracturing with the main goal of modeling fracture nucleation in porous media, for example, rocks. Built on the variational formulation of previous phase-field methods, the proposed model incorporates the material strength envelope for hydraulic fracture nucleation through two important steps: (i) an external driving force term, included in the damage evolution equation, that accounts for the material strength; (ii) a properly designed damage function that defines the fluid pressure contribution on the crack driving force. In conclusion, the comparison of numerical results for two-dimensional test cases with existing analytical solutions demonstrates that the proposed phase-field model can accurately model both nucleation and propagation of hydraulic fractures. Additionally, we present the simulation of hydraulic fracturing in a three-dimensional domain with various stress conditions to demonstrate the applicability of the method to realistic scenarios.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

CTH v.13.0

SAND2023-06647O The latest version of the CTH suite of computer codes is a flexible software system designed to treat a wide range of shock wave propagation and material motion phenomena in 1-D, 2-D, or 3-D. CTH has models suitable for most conditions encountered in shock physics including material strength, fracture, distended materials, high explosives, and a variety of boundary conditions. Finite-volume analogs of the Lagrangian equations of momentum and energy conservation are employed with continuous rezoning to construct Eulerian differencing. Adaptive mesh refinement is available for maximizing resolution in regions of interest. Full Lagrangian numerical methods are available for mechanical or structural response.

Schumacher, Shane↗
DOE OSTI2024

High-throughput quantification of quasistatic, dynamic and spall strength of materials across 10 orders of strain rates

Abstract The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are achieved using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure–property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven microflyer (LDMF) shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain-rate regimes. The LDMF shock system can test samples through impact loading, triggering spall failure. The model material used for testing is magnesium alloys, which are lightweight, possess high-specific strengths, and have historically been challenging to design and strengthen due to their mechanical anisotropy. We adopt two distinct microstructures, solutionized (no precipitates) and peak-aged (with precipitates) to demonstrate interesting upticks in strain-rate sensitivity and evolution of dynamic strength. At high shock-loading rates, we unravel an interesting paradigm where the spall strength vs. strain rate of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high-throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of materials for extreme environments.

Eswarappa Prameela, Suhas (ORCID:0000000334530184)↗
DOE OSTI2024

Determining reference standard strength for neutron-irradiated reduced activation ferritic/martensitic steel F82H by Bayesian method

The deterministic approach widely adopted in the design of structural components relies on systematically defined design limits using empirically determined safety factors. However, this approach is not always appropriate because structures are subjected to a variety of loads in the practical environment, which may result in excessively conservative design limits. In recent years, a more rigorous probabilistic approach that incorporates material strength distributions has become an important solution. In the probabilistic approach, the probability density functions of material strength properties underpin the design criteria. Here, the objective of this study is to identify the density distribution functions that best describe tensile properties of irradiated F82H to define a reference strength for DEMO design. Due to the limited number of existing data, this study specifically employs a Bayesian prediction method based on Monte Carlo simulations to determine a material reference value with statistical reliability and to investigate its effectiveness. For example, the dependence of tensile properties of 300 °C irradiated materials on irradiation damage and the range predicted by 95% Bayesian estimation was evaluated. As a statistical model for the dose dependence of statistical parameters, the normal distribution exhibited a better fit for 0.2% proof strength and tensile strength, whereas the distribution of total elongation data gave comparable reference values for both the normal and Weibull distribution models. Both models gave comparable criteria for the distribution of total elongation data. The Weibull model also gave better results for uniform elongation. The function best describing the model was a logarithmic law for both 0.2% proof strength and tensile strength, while a power law for both total and uniform elongation, which allowed for more comprehensive data prediction of irradiation data with statistical accuracy for DEMO reactor design.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Modeling Solids in Nuclear Astrophysics with Smoothed Particle Hydrodynamics

Abstract Smoothed particle hydrodynamics (SPH) is a frequently applied tool in computational astrophysics to solve the fluid dynamics equations governing the systems under study. For some problems, for example when involving asteroids and asteroid impacts, the additional inclusion of material strength is necessary in order to accurately describe the dynamics. In compact stars, that is white dwarfs and neutron stars, solid components are also present. Neutron stars have a solid crust, which is the strongest material known in nature. However, their dynamical evolution, when modeled via SPH or other computational fluid dynamics codes, is usually described as a purely fluid dynamics problem. Here, we present the first 3D simulations of neutron star crustal toroidal oscillations including material strength with the Los Alamos National Laboratory SPH code FleCSPH. In the first half of the paper, we present the numerical implementation of solid material modeling together with standard tests. The second half is on the simulation of crustal oscillations in the fundamental toroidal mode. Here, we dedicate a large fraction of the paper to approaches that can suppress numerical noise in the solid. If not minimized, the latter can dominate the crustal motion in the simulations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Impact of breech geometry and propellant flow on the release of large pellets for the ITER disruption mitigation system

Studies have been performed on the release mechanism for large pellets using high pressure gas in a shattered pellet injector. Typically, pellets are dislodged from the cryogenic surface and accelerated down a barrel using high pressure gas delivered by a fast-acting propellant valve. The pellets impact an angled surface which shatters the pellet into many small fragments before entering the plasma. This technique was initially demonstrated on DIII-D (Commaux et al 2016 Nucl. Fusion 56 046007) and is now deployed on JET, KSTAR, ASDEX-Upgrade, and other tokamaks around the world in support of ITER's disruption mitigation system design and physics basis. The large hydrogen, 28.5 mm diameter, 2 length-to-diameter ratio, pellets foreseen for ITER SPI operation have low material strength and low heat of sublimation, which cause the pellets to be fragile and highly reactive to the impact of warm propellant gas. Due to the size of the pellets, significantly more propellant gas is required to dislodge and accelerate them. This creates a potentially significant propellant gas removal issue as 2–6 bar-L of gas is expected to be required for release and speed control. The research presented in this paper is an in-depth exploration of the parameters that are keys to reliable pellet release and speed control. Computational fluid dynamics (CFD) modeling of propellant flows through various breech designs was conducted to determine the force generated on the back surface of a pellet. These simulations assumed the use of the ORNL designed flyer plate valve. CFD modeling combined with experimental measurements provide adequate insight to determine a path to an optimal valve and breech design for ITER SPI pellet release and speed control while minimizing propellant gas usage.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Crack Propagation Modeling of a High-Speed Outer Rotor Motor

This study aims to investigate the propagation of initial cracks in electric motors and their rate of spread through the rotor structure under various operating conditions. Traction motors are subjected to high centrifugal load owing to their speed and rapid acceleration and deceleration. In the manufacturing process, some initial imperfections or cracks in the rotor components are likely to occur. Under the influence of loading, these cracks will grow, and factors such as loading frequency, material strength, and location of material voids will affect this threshold speed. In the current study, a fracture mechanics–based approach has been used to investigate the crack growth rate for a 100 kW outer rotor motor with a rated speed of 6,000 rpm and a peak speed of 20,000 rpm for an integrated drive application.

Barua, Himel↗