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DOE OSTI2018

Utah FORGE: Stress Logging Data

This spreadsheet consist of data and graphs from deep well 58-32 stress testing from 6900 - 7500 ft depth. Measured stress data were used to correct logging predictions of in situ stress. Stress plots shows pore pressure (measured during the injection testing), the total vertical in situ stress (determined from the density logging) and the total maximum and minimum horizontal stresses. The horizontal stresses were determined from the DSI (Dipole Sonic Imager) and corrected to match the direct measurements.

15 GEOTHERMAL ENERGY↗

DOE OSTI2018

Optimization of hot workability and microstructure control in a 12Cr-10Ni precipitation hardenable stainless steel: An approach using processing maps

Highlights: • Deformation processing map was developed for a 12Cr10Ni precipitation hardenable martensitic stainless steel and optimized hot working parameters were suggested to obtain defect free products. • The ‘stable’ domain of the processing maps were correlated to the dynamic recrystallization in the austenite phase and further confirmed by detailed microstructural investigations. • The DRx domain showed a refinement of the martensite packet size and of the prior transformation austenite grain size, essential to obtain the desired mechanical properties. - Abstract: Optimization of hot working parameters and corresponding microstructure control were explored in a 12Cr-10Ni precipitation hardenable martensitic stainless steel. From hot compression tests, 1073–1373 K (800°–1100 °C) and five (0.001–10 s{sup −1}) different strain rates, processing maps were developed, and various domains of microstructure evolution (in the austenite phase) were identified. The stable domain of the processing maps appeared to indicate dynamic recrystallization (DRx) in the austenite phase: as evident by the appearance of inflection point in the strain hardening rate versus flow stress plots. The suspected DRx domain was further confirmed by detailed microstructural investigations of the respective water-quenched specimens. The DRx domain showed a refinement of the martensite packet size and of the prior transformation austenite grain size. The later was shown with optical microstructure and reconstructed (modelled) microtexture data of the prior austenite grains. Additionally, the DRx domain showed a significant difference in activation energy as estimated from appropriate constitutive modelling.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Shock melting and the hcp-bcc phase boundary of Mg under dynamic loading

The high-temperature and high-pressure response of magnesium has been investigated through shock-release experiments performed up to shock melting. The longitudinal and bulk sound speeds of Mg are reported along the Hugoniot from 25 to 56 GPa and used to determine the elastic properties and Grüneisen parameter. The hexagonal close-packed (hcp)–body-centered cubic (bcc) phase transition is marked by a reduction in the determined shear wave speed. Thermal softening is observed to begin between 40 and 44 GPa, with incipient melt at 55.5 GPa, in close agreement with previous diffraction measurements under laser shock loading. Examination of the release profiles showed that two different responses were observed, depending on the peak stress. When plotted in a stress-energy phase diagram, the two responses are observed to form separate lines that intersect the static hcp-bcc phase transition and incipient melt. The results indicate that the hcp-bcc transition occurs on the Hugoniot at 28.4 GPa and place the hcp-bcc-liquid triple point ~20 GPa. In conclusion, a multiphase equation of state is developed which places the melt boundary below the previously reported static measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Nanoindentation Stress–Strain for Fracture Analysis and Computational Modeling for Hardness and Modulus

Stress–Strain plots based on nanoindentation load–depth curves were obtained to study phenomena like internal fracture and ductile to brittle transitions. Fracture phenomena during the indentation process were analyzed based on the stress–strain plots. A transition from ductile to brittle fracture was observed on increasing the depth or load of indenter penetration. A new approach with shape factors in the fracture studies based on radial crack branching and micro-cracking was done. Hardness and modulus plots were fitted with polynomials. The fitting parameters were varied to obtain different hardness and modulus responses.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Micropillar Tests of As-received and Irradiated FeCrAl C26M Alloys

The present report summarizes the efforts to investigate the deformation behavior of a FeCrAl C26M alloy before and after irradiation. In order to clarify the mechanical effects of radiation-induced defects along different crystallographic orientations, micropillars with the dimension of 600 nm in diameter and 1.3 um in height have been fabricated inside grains with different orientations. When compressed along [001] direction, it was found that the yield stress has increased from 630 MPa to 750 MPa at an average dpa level of 1 (peak dpa ~ 2.7), and to 850 MPa at 16 average dpa (peak dpa ~ 42.7). In addition, due to the appearance of radiation-induced defects, strain hardening response has been changed as well. Especially, when the flow stressis lower than 1.5 GPa, hardening response has been captured, which is due to the collective interaction of various shear bands. However, when the flow stress increases to larger than 1.5 GPa, another mode of shear band has been captured. The correlated process is at least ten times faster, corresponding to the sudden load drop in the stress strain plot. When the compression has been applied along [011] and [111] direction, the increase of yield stress after irradiation has also been captured. However, the correlated magnitude is different: yield stress of [011] increases from 500 MPa to 700 MPa at 1 dpa and to 1200 MPa at 16 dpa. On the other hand, when the compressive loading has been employed along [111], the correlated yield stress changes from 500 MPa to 700 MPa at 1 dpa and to 1400 MPa at 16 dpa. Moreover, the second mode of shear band has also been recorded in the 16 dpa irradiated sample when stress applied along [011], but not shown along [111] direction.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Influence of Growth Rate on Eutectic Spacing, Microhardness, and Ultimate Tensile Strength in the Directionally Solidified Al-Cu-Ni Eutectic Alloy

In this work, the mechanical properties of the Al-Cu-Ni eutectic alloy, Al-32.5 wt pct Cu-1 wt pct Ni, were investigated in terms of the dependency on growth rates. The Al-Cu-Ni eutectic alloy was directionally solidified at a constant temperature gradient, G = 4.93 K mm{sup −1}, with a wide range of growth rates (V = 9.25 to 2056.68 µm s{sup −1}) using a Bridgman-type directional solidification furnace. The eutectic spacing (λ), microhardness (HV{sub T}), and ultimate tensile strength (σ{sub UTS}) were measured with standard techniques. The dependences of λ, HV{sub T}, and σ{sub UTS} on V for directionally solidified Al-Cu-Ni eutectic alloy were experimentally obtained using regression analysis. The results obtained in the present work were compared with the similar experimental results in the literature. Finally, the elastic energy dependence on growth rates for Al-32.5 wt pct Cu-1 wt pct N alloy was determined from their nominal stress–strain plots.

36 MATERIALS SCIENCE↗

DOE OSTI2026

ACT University Collaboration Proposal: Role of manufacturing defects on material failure under dynamic loading for developing enhanced failure models and theories (Final Report)

Research on the tensile behavior of additively manufactured 316L stainless steel coupon specimens at increasing strain rates was conducted over the past year at Penn State. Dynamic loading rates into the 1000 1/s loading rates were performed on specimens with nearly 1.32” gage lengths. Stress-strain plots show ductile and plastic behavior well beyond 12% strain with necked specimens, having smaller effective gage lengths showing up to 56% ultimate strain. Additional tests performed on compact tension specimens helped with simulation work to understand the deformation behavior. Using finite elements, it was possible to determine the feasibility of a comprehensive experimental validation study towards an improved model for AM material failure – specifically, the Bai-Wierzbicki approach which accounts for lode angle and triaxiality. A non-significant number of tests are projected for eight specific failure nodes, with additional replicates to provide strain-rate capabilities to the existing formulation. One such correction factor is explored for quasi-static, notched specimens. Finally, stress intensity factor was explored using a set of compact-tension specimens which would also provide useful validation data for any simulation work.

36 MATERIALS SCIENCE↗

DOE OSTI2023

In situ mechanical characterization of a single cell-cell adhesion interface under large strain

A method of measuring a stress-strain curve in a cell-cell adhesion interface, the method including: providing a structure including a first movable island supported by a first beam, a second movable island supported by a second beam, and a gap therebetween connected by a pair of cells forming a junction, the pair of cells comprising a cell-cell adhesion interface having an initial length defined by a distance between nuclei of the pair of cells; moving the second movable island with a defined displacement; determining a displacement of the first movable island based on moving the second movable island; calculating a difference between the displacement of the first movable island and the defined displacement of the second movable island based on moving the second movable island; determining an applied strain in the cell-cell adhesion interface between the pair of cells based on the difference divided by the initial length of the cell-cell adhesion interface; calculating a force between the cell-cell adhesion interface of the pair of cells based on the displacement of the first movable island; calculating a stress in the cell-cell adhesion interface between the pair of cells based on the force; and determining the stress-strain curve of the cell-cell adhesion interface between the pair of cells by plotting the calculated stress against the applied strain.

Yang, Ruiguo↗

DOE OSTI2023

A direct numerical simulation study for confined non-isothermal jet impingement at moderate nozzle-to-plate distances: Capturing jet-to-ambient density effects

A direct numerical simulation (DNS) campaign is deployed for a series of confined downward oriented, non-isothermal turbulent impinging jet configurations. A baseline Reynolds number of 9960 is obtained through a precursor DNS pipe flow simulation (Re τ = 505). Three jet temperature configurations (confinement height to nozzle diameter of three) enter a cylindrical domain that share ambient and impingement plate temperatures (298.15 K). The range of jet temperatures are crafted such that the ratio of inlet to ambient density varies from unity to 0.52, showcasing the effect of density disparity on flow characteristics such as core collapse, radial mixing of momentum and energy, near-wall stagnation behavior, wall-jet profiles, and large-scale vortical structures. Surface quantities provided include mean radial heat flux and wall-shear stress profiles, and heat flux histograms at select radial stations. Results showcase increased radial normal stresses for higher temperature jets that support increased mixing, resulting in large-scale recirculation structures that are smaller, while retaining similar normalized radial wall profiles for shear stress, heat flux and pressure. Furthermore, radial plots for wall shear stress and Nusselt number showcase strong radial decay as compared to previous configurations that share similar jet and ambient temperatures. For the 373.15 K case, a Gaussian-like histogram for heat fluxes at the impingement plate transitions to a log-normal profile as radial distances increase. In contrast, the 573.15 K configuration displays a bi-modal heat flux characteristic at the impingement plate, and in similar manner to the moderate temperature counterpart, transitions to a log-normal profile at larger radial distances.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Development of an Advanced Finite Element Model and Parametric Study to Evaluate Cement Sheath Barrier

Cement failure is known as one of the major causes for loss of well control events. Cement design is considered as one of the top technological knowledge gaps in high-pressure high-temperature oil and gas exploration. The primary objective of this paper is to perform a parametric analysis and identify critical parameters affecting the mechanical integrity of the set cement sheath. To achieve the objective, three-dimensional finite element models consisting of concentric casings and annular cement sheath were created. The finite element model was validated by analytical calculations. Performance of cement sheath was assessed by analyzing radial, hoop, and maximum shear stresses at different loading conditions. A parametric study was conducted by individually varying influencing factors such as cement material properties, sheath dimensions, and wellbore pressure loads. Values of all parameters were normalized and represented on the same plot against mechanical stresses. Such response curves can be used to estimate whether cement will structurally fail because of various operational loads or material aging. The plot can also be utilized to rank various factors in terms of influence on cement’s performance. Sensitivity response reveals that wellbore pressure, cement material properties, and annulus pressure are major parameters influencing mechanical stresses in neat class G cement. The order of importance depends on the type of stress. Results indicate interfacial bond failure and radial cracking to be the more likely modes of failure for class G cement. Cement response curves can help design engineers and regulators alike in quickly evaluating short-term or long-term fitness-for-service of cement sheath from the perspective of structural integrity. Industry standards and guidelines can be improved by adding performance curves for standard cement recipes.

Energy & Fuels↗

DOE OSTI2017

Characterization of Shear Properties for APO/MBI Syntactic Foam

Triaxial compression testing is a means for mechanical characterization of a material. A unique feature of the triaxial compression test is the application of two different magnitudes of compressive pressures on the material simultaneously. The material behavior under these different compressive pressures can be monitored over time. Several important characteristics of the material, such as stress yield values and the shear failure envelope may then be determined. Also mechanical properties such as Poisson’s ratio, Young’s modulus and bulk modulus can be determined from the triaxial compression test. The triaxial compression test was employed in this investigation to characterize the shear behavior, shear failure envelope, and mechanical properties of a syntactic foam. Los Alamos National Laboratory (LANL) supplied a total of 36 samples of APO-BMI syntactic foam to the University of New Mexico, Department of Civil Engineering for testing between December 2003 and May 2004. Each sample had a diameter of 1.395±0.005 in. (3.543±0.013cm.) and a length of 2.796±0.004 in. (7.102±0.010 cm.). The samples had an average density of 0.295 g/cm3. Additional information about the material tested in this investigation can be found in the “Specimen Description” section contained in Chapter 1. The nomenclatures used in this study is presented in Chapter 1. In addition to designing and implementing triaxial compression tests capable of up to 2,000 psi. confining pressure (minor principal stress) and roughly 13,000 psi. in axial pressure (major principal stress), a pure tension test was designed and conducted on the foam material. The purpose of this pure tension test was to obtain maximum tensile stress values to enhance the characterization of the shear envelope in the stress space. The sampling procedure and specimen preparation for a standard test can be found in the American Society for Testing Materials (ASTM) D 5379/ D 5379 – 93. The above tests mentioned and their procedures are discussed in Chapter 2. Chapter 2 contains the types of tests performed and the apparatus used for testing the material. Chapter 2 also has a brief explanation of the equipment and the procedures used for conducting the tests. In Chapter 3, the material characteristics and mechanical properties obtained from the tests are described; composite plots of deviatoric vs. mean stress and deviatoric stress vs. longitudinal strain are also included. The plots of deviatoric stress vs. mean stress clearly identify the shear envelope for the material. Chapter 4 summarizes the vital information obtained from the tests and the conclusions made. All the necessary plots and the data generated during the testing have been included in the Appendix. The information in the appendix includes plots of: Strain vs. Time, Stress vs. Time, Stress vs. Strain, Mean Stress vs. Volumetric Strain, Lateral Strain vs. Longitudinal Strain, and q vs. p. Bulk modulus, Poisson’s ratio, and Young’s modulus are displayed in the appropriate plots in each appendix.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Trait relationships of fungal decomposers in response to drought using a dual field and laboratory approach

Abstract Decomposer fungi play a fundamental role in terrestrial ecosystem dynamics. In the southwestern United States, climate change is causing more frequent and severe droughts, which may alter fungal community composition and activity. Investigating relationships between fungal traits may improve the prediction of fungal responses to drought. In this dual field and laboratory experiment, we examine whether trade‐offs occur between traits associated with drought. Specifically, we test the hypothesis that fungi sort into lifestyles specializing in growth y ield, resource a cquisition, and drought s tress tolerance (“YAS” framework). For the field experiment, we constructed microbial “cages” containing sterilized litter and 1 of 10 fungal isolates. These cages were placed in long‐term drought and control plots in a southern Californian grassland for 6 and 12 months. We measured fungal hyphal length per unit litter mass loss for growth yield, the potential activities of four extracellular enzymes for resource acquisition, and the ability to grow in the drought versus control plots for drought stress tolerance. We compared these results with a laboratory microcosm experiment constructed with the same fungal isolates and that measured the same fungal traits. The field experiment corroborated our laboratory results, in that no trade‐offs were observed between growth yield and resource acquisition traits. However, in contrast to the laboratory experiment, drought tolerance was negatively related to extracellular enzyme activity and growth yield in the field, implying a trade‐off. Despite this observed trade‐off in the field, growth yield was not hindered by drought. We propose a modification to the YAS framework, by combining the growth yield and resource acquisition lifestyles, which may be more appropriate for this arid system. This joint laboratory and field approach contextualizes a theoretical framework in microbial ecology and improves understanding of fungal community response to climate change.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Empirical Characterization and Modeling of Cohesive – to – Adhesive Shear Fracture Mode Transition due to Increased Adhesive Layer Thicknesses of Fiber Reinforced Composite Single – Lap Joints

Here, to ensure a strong adhesive bond, most standards and adhesive manufacturers specify a maximum adhesive gap of 1 mm when bonding fiber reinforced composite structures. In manufacturing large components, such as joining two halves of wind turbine blades, meeting this gap tolerance specification is impractical; gaps larger than 10 mm are common in large adhesively bonded composite structures using state-of-the-art manufacturing techniques. Currently, there is a lack of fundamental understanding of the failure mechanics of adhesive gaps larger than 3 mm. To create such understanding, glass fiber - acrylic thermoplastic composite panels bonded using different epoxy adhesives within single-lap joint samples with adhesive thicknesses of 0.1 mm, 0.3 mm, 1 mm, 3 mm, 5 mm, and 10 mm were sheared to failure. A transition from cohesive to adhesive failure was observed to occur about 1 mm to 3 mm joint thicknesses. Plotting the shear stress normalized by the ratio of the joint width to thickness as a function of the joint thickness normalized by the joint length is shown to result in the ability to fit simple empirically derived models of the cohesive-to-adhesive failure transition, regardless of the adhesive. Furthermore, using these normalized variables, all the observed cohesively failed specimens collapse to a single master curve, as do the adhesively failed specimens.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Optimal Geometry for Focused Ion Beam-Milled Samples for Direct-Pull Micro-Tensile Testing Performed In Situ in a Scanning Electron Microscope

A thorough procedure was developed to efficiently manufacture dogbone samples using focused ion beam (FIB) milling for micro-tensile testing. A Bruker PI 89 PicoIndenter, Billerica, MA, USA, was used as a case study, although the analysis and results are applicable to other micro-mechanical testing systems capable of mounting a standard, Ø12.7 mm × Ø3.2 mm pin, scanning electron microscopy (SEM) pin stub (Ted Pella, Redding, CA, USA). Nine dogbones were made from an Fe-45Cu alloy additively manufactured using powder-fed laser-directed energy deposition (DED-LB). Testing showed that fracture was confined to the gauge section for all dogbones and that the fracture mode, ductile vs. brittle, was entirely dependent on the grain orientation relative to the loading direction. The analysis showed that the measured plastic strain to failure can vary from >11% (optimal geometry) to <1% (non-optimal geometry) in micro-tensile testing of high-tensile-strength (>1 GPa) metallic materials. Subsequently, a finite element analysis (FEA) was conducted to identify the improved dogbone geometries. A total of ten thousand dogbone geometries were tested, and their dimensions were defined by a set of four adjustable parameters (corner radius, load surface angle, load surface length, and dogbone head length). The gauge width and gauge length were fixed to 4 µm and 10 µm, respectively. Three-dimensional surface plots of the stress concentration as a function of two parameters were used to identify the optimal ranges of parameter values. The addition of maximum width and length constraints, measuring 25 µm and 30 µm, respectively, allowed us to identify an optimal geometry at load surface angles of 30° and 45°. Their respective dimensions (corner radius, load surface length, and dogbone head length) are, in µm, 12, 6, and 7 and 10, 7, and 7. Testing these two optimal geometries with a range of gauge lengths from 4 to 20 µm showed that smaller gauge lengths only slightly reduced the detrimental stress concentration outside the gauge section. However, smaller gauge lengths will notably improve the FIB surface polishing step as tapering is reduced with smaller dogbone lengths.

Chemistry↗

DOE OSTI2018

Fallon FORGE: Distinct Element Reservoir Modeling

Archive containing input/output data for distinct element reservoir modeling for Fallon FORGE. Models created using 3DEC, InSite, and in-house Python algorithms (ITASCA). List of archived files follows; please see 'Modeling Metadata.pdf' (included as a resource below) for additional file descriptions. Data sources include regional geochemical model, well positions and geometry, principal stress field, capability for hydraulic fractures, capability for hydro-shearing, reservoir geomechanical model-stimulation into multiple zones, modeled thermal behavior during circulation, and microseismicity.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Dynamic phase transformations in additively manufactured Ti-6Al-4V during thermo-mechanical gyrations

A complex interaction of process parameters, geometry and scan strategies in Additive Manufacturing (AM), can bring about spatial and temporal transients, i.e., Σ T ( x, y, z, time ), within a part. Published literature focusses on fluctuating thermal cycles on the microstructure evolution. However, the microstructural variations have not been correlated to dynamic flow behavior due to the macro- and micro-scale phenomena, i.e., accumulated plastic strains brought about by large thermal gradients, transformational strains and crystallographic misfit strains. Therefore, here we studied the mechanical response of Ti6Al4V alloys produced by AM under externally imposed controlled thermo-mechanical reversals in a Gleeble® thermo-mechanical simulator. The stress-strain behaviors were correlated to phase fractions, lattice strains, and also limited information on crystallographic texture using neutron diffraction techniques at the VULCAN Beamline at SNS, ORNL and also metallographic studies. The results are discussed and rationalized based on theories of static and dynamic phase transformations.

36 MATERIALS SCIENCE↗

DOE OSTI2020

SupplementalFilesCPTAC_ProteogenomicOvarianPaper_2020_02_27

Interactive plots (in HTML/javascript) as supplemental files for the paper titled: Proteogenomic Characterization of Ovarian High-Grade Serous Cancer Implicates Mitotic Kinases, Replication Stress in Observed Chromosomal Instability. The plots represent the differential expression of proteins (File 1) and phosphopeptides (File 2) comparing tumor to normal tissue.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Critical Shear Stress for Erosion Under Laminar Jet Flow

Particle erosion is an important process in both natural and manmade environments. For example, in natural environments particle or sediment erosion rates determine the course of rivers, depth of streams, and fate of deltas. The interplay between erosion rates and flow patterns can have dramatic impact on shorelines. Where hydrodynamic jet flows or rip currents change direction, sediments may accumulate or disperse altering the shape of coastlines and the ecosystems and economies that rely on them. In man-made systems, jet flows may be used to mobilize particles from surfaces or within industrial scale mixing tanks. For example, in the nuclear industry, impinging jet mixers may be used to mobilize and suspend sludges at the bottom of waste tanks. In each of these examples, the Shields diagram is useful to determine the conditions under which erosion occurs. This diagram plots the scaled critical shear stress for erosion as a function of the particle size as embedded in particle Reynolds numbers, Archimedes numbers, or their equivalents. Although the data, that carries a large spread, is largely in agreement with mathematical models, for the smallest particles, model predictions diverge from each other and from experimental data. Indeed, there is substantial uncertainty about the Shields diagrams at relatively small particle sizes and flow rates. Here we evaluate critical shear stresses for erosion under laminar jet flow. To date critical shear stresses for erosion, as embodied in Shields diagrams, have largely been developed for turbulent flow both experimental and mathematically. However, curves on the Shields diagrams diverge among various models at lower particle Reynolds numbers. Indeed, how critical shear stresses for erosion develop under fully laminar jet flow conditions (not simply laminar boundary layers under turbulent flow) remains unclear. Here we address this gap, which is particularly important for mobilization of the smallest particles. We find the Shields parameter to be inversely proportional to the particle Reynolds numbers under laminar jet flow conditions similar to turbulent conditions.

critical shear stresses, erosion rates, effective ↗