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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2011

Finite Element Simulation of Machining of Ti6Al4V Alloy

Titanium and its alloys are an important class of materials, especially for aerospace applications, due to their excellent combination of strength and fracture toughness as well as low density. However, these materials are generally regarded as difficult to machine because of their low thermal conductivity and high chemical reactivity with cutting tool materials. Moreover, the low thermal conductivity of Titanium inhibits dissipation of heat within the workpiece causing an higher temperature at the cutting edge and generating for higher cutting speed a rapid chipping at the cutting edge which leads to catastrophic failure. In addition, chip morphology significantly influences the thermo-mechanical behaviour at the workpiece/tool interface, which also affects the tool life.In this paper a finite element analysis of machining of TiAl6V4 is presented. In particular, cutting force, chip morphology and segmentation are taken into account due to their predominant roles to determine machinability and tool wear during the machining of these alloys. Results in terms of residual stresses are also presented. Moreover, the numerical results are compared with experimental ones.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Finite element analyses of single particle crushing tests incorporating computed tomography imaging and damage mechanics

Fracture of individual grains within a granular assembly affect the strength and deformation behavior of granular materials under large stress states. Interparticle forces, leading to contact stresses and ultimately fracture initiation, are influenced by particle morphology. A numerical method that incorporates both particle fracture and morphology can provide a more accurate model of a granular material’s macro-scale response. This research investigates an approach to modeling fracture initiation and propagation within individual grains, utilizing high resolution X-ray computed tomography (CT) imaging to consider grain morphology and an explicit finite element code optimized for high performance computing which incorporates damage mechanics. Using precisely measured force-displacement curves from single particle crushing tests of manufactured quartz spheres, the method is validated, and the effects of fracture properties on grain fragmentation are determined. This approach is then used to simulate single particle crushing of Ottawa sand, with grain morphology incorporated through discretized CT images. Here the effect of grain orientation on the force and applied displacement at catastrophic splitting is also explored. The proposed discrete particle based finite element framework can be applied to modeling granular assemblies, considering the effect of individual particle shape and fracture on the assembly’s deformation response through well calibrated numerical simulations.

42 ENGINEERING↗
DOE OSTI2018

Metal plasticity and ductile fracture modeling for cast aluminum alloy parts

Here in this study, plasticity and ductile fracture properties were characterized by performing various tension, shear, and compression tests. A series of 10 experiments were performed using notched round bars, flat-grooved plates, in-plane shear plates, and cylindrical bars. Two cast aluminum alloys used in automotive suspension systems were selected. Plasticity modelling was performed and the results were compared with experimental and corresponding simulation results; further, the relationships among the stress triaxiality, Lode angle parameter, and equivalent plastic strain at the onset of failure were determined to calibrate a ductile fracture model. Finally, the proposed ductile fracture model shows good agreement with experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2022

From Fluid Flow to Coupled Processes in Fractured Rock: Recent Advances and New Frontiers

Abstract Quantitative predictions of natural and induced phenomena in fractured rock is one of the great challenges in the Earth and Energy Sciences with far‐reaching economic and environmental impacts. Fractures occupy a very small volume of a subsurface formation but often dominate fluid flow, solute transport and mechanical deformation behavior. They play a central role in CO 2 sequestration, nuclear waste disposal, hydrogen storage, geothermal energy production, nuclear nonproliferation, and hydrocarbon extraction. These applications require predictions of fracture‐dependent quantities of interest such as CO 2 leakage rate, hydrocarbon production, radionuclide plume migration, and seismicity; to be useful, these predictions must account for uncertainty inherent in subsurface systems. Here, we review recent advances in fractured rock research covering field‐ and laboratory‐scale experimentation, numerical simulations, and uncertainty quantification. We discuss how these have greatly improved the fundamental understanding of fractures and one's ability to predict flow and transport in fractured systems. Dedicated field sites provide quantitative measurements of fracture flow that can be used to identify dominant coupled processes and to validate models. Laboratory‐scale experiments fill critical knowledge gaps by providing direct observations and measurements of fracture geometry and flow under controlled conditions that cannot be obtained in the field. Physics‐based simulation of flow and transport provide a bridge in understanding between controlled simple laboratory experiments and the massively complex field‐scale fracture systems. Finally, we review the use of machine learning‐based emulators to rapidly investigate different fracture property scenarios and accelerate physics‐based models by orders of magnitude to enable uncertainty quantification and near real‐time analysis.

58 GEOSCIENCES↗
DOE OSTI2022

Understanding the Elastic, Plastic, and Damage Features in Fracturing of Self-reinforced Thermoplastic Composites via Non-destructive Digital Imaging Correlation

This work demonstrated the utilization of non-destructive Digital Imaging Correlation (DIC) method to characterize the elastic, plastic, and damage features during the Mode I intra-laminar fracturing process of self-reinforced thermoplastic composites by using a self-reinforced polypropylene (PP) composite as an example. The DIC results clearly showed the development of huge plastic zone (PZ) and non-negligible Fracture Process Zone (FPZ) in front of the notch tip during the fracturing process, and the geometries and sizes of the foregoing zones at the peak load were further quantified. Such an interesting fracturing behavior of self-reinforced thermoplastic composites is way different from brittle materials (e.g., glass, acrylic, etc.), ductile materials (e.g., aluminum, steel, etc.), and even quasi-brittle materials (e.g., concrete, nanoparticle-reinforced composites, tough ceramics, wood, cement, carbon/glass fiber-reinforced polymers, etc.). Thus, understanding the elastic, plastic, and damage features is the first step before better characterizing the material fracture properties of self-reinforced thermoplastic composites through new analytical methods and computational modeling. These efforts are of utmost importance for wide applications of self-reinforced thermoplastic composites in various engineering fields in the future.

Lightweight Composites, Self-reinforced Thermoplas↗
DOE OSTI2015

Cohesive Zone Modeling in Geomaterial

The purpose of the two projects discussed in this report is to use the cohesive zone method to evaluate fracture properties of geomaterials. Two experimental tests, the push-out test and the notched three-point bend test, were modeled computationally using finite element analysis and cohesive zone modeling to extract load and displacement information and ultimately determine failure behavior. These results are to be compared with experimental tests when they are available. The first project used the push-out test to investigate the shear bond strength at the cement- shale interface. The second project explored the effects of scaling a notched three-point bending specimen to study fracture toughness characteristics. The bond strength and fracture toughness of a material and its interfaces are important parameters to consider in subsurface applications so that zonal isolation can be achieved.

42 ENGINEERING↗
DOE OSTI2017

Chemical Tool Peer Review Summary.

Chemical tracers are commonly used to characterize fracture networks and to determine the connectivity between the injection and production wells. Currently, most tracer experiments involve injecting the tracer at the injection well, manually collecting liquid samples at the wellhead of the production well, and sending the samples off for laboratory analysis. While this method provides accurate tracer concentration data, it does not provide information regarding the location of the fractures conducting the tracer between wellbores. The goal of this project is to develop chemical sensors and design a prototype tool to help understand the fracture properties of a geothermal reservoir by monitoring tracer concentrations along the depth of the well. The sensors will be able to detect certain species of the ionic tracers (mainly iodide) and pH in-situ during the tracer experiment. The proposed high-temperature (HT) tool will house the chemical sensors as well as a standard logging sensor package of pressure, temperature, and flow sensors in order to provide additional information on the state of the geothermal reservoir. The sensors and the tool will be able to survive extended deployments at temperatures up to 225 °C and high pressures to provide real-time temporal and spatial feedback of tracer concentration. Data collected from this tool will allow for the real-time identification of the fractures conducting chemical tracers between wellbores along with the pH of the reservoir fluid at various depths.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Mapping of fracture and ionic conductivity changes in ion implanted solid electrolytes: Insights from molecular dynamics

Ion implantation emerges as a promising technique to address the persistent challenge of lithium (Li) filament growth in solid-state electrolytes as it can induce compressive stresses inhibiting crack growth and deflect dendrites, de facto mitigating early electrolyte failure. In this study, we examine the potential paradox of ion implantation: while aiming to enhance electrolyte performance, the radiation damage associated with implantation might inadvertently compromise both the ionic conductivity and the intrinsic fracture toughness of the material, rendering the material unsuitable for battery applications. Specifically, we employed molecular dynamics simulations to examine the scope of the downsides of ion implantation, specifically: (i) reduced ionic conductivity (due to radiation-induced amorphization) and (ii) mechanical stability (due to radiation-induced embrittlement) in ion-implanted Li 7 La 3 Zr 2 O 12 (LLZO) solid-state electrolytes. We explore how radiation damage impacts LLZO’s crystalline structure, Li-ion diffusion, and fracture properties at various temperatures and radiation damage levels. The study aims to provide insights into the competing effects of ion implantation and suggest potential engineering strategies for developing more robust solid-state electrolytes with improved conductivity and dendrite resistance.

Conductivity↗
DOE OSTI2022

Effect of N 2 - and CO 2 -containing shielding gases on composition modification and carbonitride precipitation in wire arc additive manufactured grade 91 steel

Additive manufacturing (AM) represents a promising technique to fabricate metallic alloys with greater control of the resulting material features as compared to traditional manufacturing routes. Recently, there is greater interest in AM research on 9 wt% Cr ferritic/martensitic (F/M) steels, which are commonly studied for use in the nuclear energy industry. This work aims to prove that wire arc AM can manufacture F/M steels with adequate mechanical properties in multiple processing atmospheres and aims to study how shielding gas composition can be leveraged during fabrication to induce specific precipitation pathways. The effect of shielding gas composition on MX (M=Nb and/or V, Xdouble bondC and/or N) carbonitride precipitation in a 9 wt% Cr ferritic/martensitic (F/M) steel alloy known as Grade 91 was studied using N 2 and CO 2 gas additions to an inert Ar shielding gas atmosphere during wire arc AM. The N and C atoms present in the processing atmospheres were absorbed into the melt pools during fabrication. Due to their differing affinities for precipitate-forming reactions, the varying levels of C and N between the samples contributed to differences in final carbonitride composition and morphologies. Such precipitate behavior is of interest as carbonitrides have been shown to contribute to increased mechanical performance. This increased performance was studied via electron microscopy and tested for strength, ductility, and fracture properties.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Skin factor and potential formation damage from chemical and mechanical processes in a naturally fractured carbonate aquifer with implications to CO 2 sequestration

Here, in this study, we investigate formation damage due to acidization and water injection tests into the naturally fractured carbonate Middle Duperow Formation at Kevin Dome, Montana, potentially diminishing the chance of a future successful Geological Carbon Sequestration (GCS) project. Multiple well-test analytical models, correlated with core description and lithology data, are used to determine flow behavior and communication between the water injection interval and surrounding formations. An improved three-dimensional (3D) geologic model with dual-continuum matrix and fracture properties is constructed based on most recent seismic, core, and water sample measurements. Brine injection is simulated to verify the interpretation from the analytical models, followed by CO 2 injection simulation. Geochemical calculations are performed to understand the in-situ processes that led to formation damage. Our findings suggest: (1) there are two possible scenarios that could lead to a positive total effective skin factor and permeability decline: partial penetration and formation damage; (2) analytical models indicate a positive total skin factor, contradicting results of a previous study suggesting that the well was mildly stimulated; (3) numerical simulation supports the formation damage hypothesis by matching the pressure buildup observed during the latter two brine injection tests; (4) several mechanical and chemical processes may have occurred during injection to clog the matrix/fracture system: anhydrite fines migration and/or calcite precipitation. We then make preventative suggestions for future GCS projects into carbonate reservoirs and remediation recommendations for GCS operation at the Kevin Dome.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2011

Reservoir Engineering for Unconventional Gas Reservoirs: What Do We Have to Consider?

The reservoir engineer involved in the development of unconventional gas reservoirs (UGRs) is required to integrate a vast amount of data from disparate sources, and to be familiar with the data collection and assessment. There has been a rapid evolution of technology used to characterize UGR reservoir and hydraulic fracture properties, and there currently are few standardized procedures to be used as guidance. Therefore, more than ever, the reservoir engineer is required to question data sources and have an intimate knowledge of evaluation procedures. We propose a workflow for the optimization of UGR field development to guide discussion of the reservoir engineer's role in the process. Critical issues related to reservoir sample and log analysis, rate-transient and production data analysis, hydraulic and reservoir modeling and economic analysis are raised. Further, we have provided illustrations of each step of the workflow using tight gas examples. Our intent is to provide some guidance for best practices. In addition to reviewing existing methods for reservoir characterization, we introduce new methods for measuring pore size distribution (small-angle neutron scattering), evaluating core-scale heterogeneity, log-core calibration, evaluating core/log data trends to assist with scale-up of core data, and modeling flow-back of reservoir fluids immediately after well stimulation. Our focus in this manuscript is on tight and shale gas reservoirs; reservoir characterization methods for coalbed methane reservoirs have recently been discussed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

A Machine Learning Approach to Quantitative Analysis of Enamel Microstructure from Scanning Electron Microscopy Images

Dental enamel, the outermost tissue of mammalian teeth, must withstand a lifetime of wear and cyclic contact. To meet this demand, enamel possesses a combination of high hardness and resistance to fracture, properties that are typically mutually exclusive. The impressive damage tolerance has been attributed largely to decussation of the enamel rods, the principal unit of its microstructure. As such, enamel is inspiring the design of next‐generation structural materials. However, quantitative descriptions of the decussated enamel rod microstructure remain limited due to challenges encountered in applying computed tomography and in acquiring quality images appropriate for traditional digital processing methods. Here, a machine learning segmentation method is applied to images of the enamel obtained using scanning electron microscopy to support quantitative analysis of the microstructure. A pretrained convolutional neural network is used to expand the input training image dataset to allow the training of a random forest classifier, which ultimately segments the image with a very small training set ( n = 3 images). A validation of this segmentation method is presented, in addition to its application to calculate relevant microstructural parameters for images of tooth enamel from selected mammalian species. The methodology applied here is equally applicable to other hard tissues.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Inverse measurement of stiffness by the normalization technique for J-integral fracture toughness

The single specimen normalization technique for J-integral fracture toughness has been successfully employed by several researchers to study the strongly non-linear fracture response of ductile semicrystalline polymers. As part of the normalization technique the load and the plastic component of displacement are normalized. The normalized data is then fit with a normalization function that approximates a power law for small displacements that are dominated by blunting and smoothly transitions to a linear relationship for large displacements that are dominated by stable crack extension. Particularly for very ductile polymers the compliance term used to determine the plastic displacement can dominate the solution and small errors in determining the elastic modulus can lead to large errors in the normalization or even make it ill-posed. This can be further complicated for polymers where the elastic modulus is strong strain rate dependent and simply using a 'quasistatic' modulus from a dogbone measurement may not equate to the dominant strain rate in the compact tension specimen. The current work proposes directly measuring the compliance of the compact tension specimen in the solution of J-integral fracture toughness and then solving for the elastic modulus. By comparison with a range of strain rate data the dominant strain rate can then be determined.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Measurement of Interfacial Fracture Toughness of Surface Coatings Using Pulsed-Laser-Induced Ultrasonic Waves

This research develops a new technique for the measurement of interfacial fracture toughness of films/surface coatings using laser-induced ultrasonic waves. Using pulsed laser ablation on the bottom substrate surface, strong stress waves are generated leading to interfacial fractures and coating delamination. Simultaneously, a laser ultrasonic interferometer is used to measure the normal (out-of-plane) displacement of the top surface coating in order to detect coating delamination in a non-destructive manner. We can thus determine the critical laser energy for delamination, yielding the critical stress (that is, the interfacial strength). Subsequently, to examine the interfacial fracture toughness, additional pulsed laser irradiation is applied to a pre-delaminated specimen to show that the delamination area expands. This type of interfacial crack growth can be visualized using laser ultrasonic scanning. Furthermore, the calculation of elastic wave propagation was carried out using a finite-difference time-domain method) in order to accurately estimate the interfacial stress field. In this calculation, the stress distribution around the initial delamination is calculated to obtain the stress intensity factor. Based on the experimental and computational results, interfacial fracture toughness can be quantitatively evaluated. Since this technique relies on a two-laser system in a non-contact approach, it may be useful for a quantitative evaluation of adhesion/bonding quality (including both interfacial fracture strength and toughness) in various environments.

42 ENGINEERING↗
DOE OSTI2018

Hygrothermal Effect on Composites Under In-Plane Fatigue at Stress Ratios of R = −1 and R = 0.1: An Analysis of Quasi-Isotropic Stitched Carbon Fibers

The aeronautic structures normally operate under high levels of hygroscopic moisture from the surrounding environment at different temperature ranges while in service. Under such conditions, the behavior of laminate composite submitted to cyclic or static loadings can change drastically. In order to understand those effects in stitched fabrics, fatigue tests with open-hole specimens were carried out with a stress ratio of R = −1 and R = 0.1. The specimens were fatigue-tested as provided (environmental conditions) and after exposed to hygrothermal weathering conditions. Based on evidences from recent studies available in the open literature, e.g., effect of water diffusion on epoxy matrix, the overall results indicated a significant reduction in stiffness after the specimens are exposed to hygrothermal effects. The reduction in matrix stiffness, in this case, enhanced the fatigue strength in tension–tension load (R = 0.1) when compared to the specimens in normal conditions. The opposite occurs for the specimens loaded with stress ratio of R = −1, in which the delamination mechanisms changed during the loading reversion from tension to compression that promoted early delamination. Therefore, this process reduced the fatigue life of the specimens under hygrothermal condition. Then, by fractographic investigation, it was verified fracture patterns that regard to mode II damage in R = −1, in which mode II fracture toughness is known to decrease in the presence of water molecules.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Statistical Strength Analysis of Dissimilar AA2024-T6 and AA6061-T6 Friction Stir Welded Joints

Friction stir welding has been emerged as one of the most reliable processes for joining aerospace-grade aluminum alloys. However, limited studies have been focused so far on the reliability of these joint types. In this study, the effect of welding parameters (traverse and rotation speeds) on the fracture strength of dissimilar AA2024-T6 and AA6061-T6 friction stir welded joints was statistically analyzed by the Weibull approach. Based on the results, the Weibull approach was found to be much more accurate than widely used standard deviation for evaluating the scatter of the fracture strength data. The improper selection of the process parameters not only decreased the average fracture strengths of the joints, but also scattered them around the mean value, and increased the failure probability under the same applied tension. According to the microscopic and macroscopic examinations and microhardness measurements, although the microstructural inhomogeneities caused by the improper setting of the welding parameters negatively affected the joints hardness and fracture strength, the welding defects were likely to be the most responsible factor affecting the fracture strength and its reliability.

36 MATERIALS SCIENCE↗
DOE OSTI2014

The influence of coarse aggregate size and volume on the fracture behavior and brittleness of self-compacting concrete

This paper presents the results of an experimental investigation on fracture characteristics and brittleness of self-compacting concrete (SCC), involving the tests of 185 three point bending beams with different coarse aggregate size and content. Generally, the parameters were analyzed by the work of fracture method (WFM) and the size effect method (SEM). The results showed that with increase of size and content of coarse aggregate, (a) the fracture energy increases which is due to the change in fractal dimensions, (b) behavior of SCC beams approaches strength criterion, (c) characteristic length, which is deemed as an index of brittleness, increases linearly. It was found with decrease of w/c ratio that fracture energy increases which may be explained by the improvement in structure of aggregate-paste transition zone. Also, the results showed that there is a correlation between the fracture energy measured by WFM (G{sub F}) and the value measured through SEM (G{sub f}) (G{sub F} = 3.11G{sub f})

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydro-chemo-mechanical phase field formulation for corrosion induced cracking in reinforced concrete

Steel corrosion induced cracking in reinforced concrete structures is often caused by volumetric straining at the steel-concrete interface. This volumetric strain is mainly controlled by the rate of generation of corrosion product, which depends on the diffusion of Cl{sup −} and dissolved O{sub 2} as well as the chemical reaction at the steel-concrete interface. While many numerical modeling techniques have been proposed to tackle this complex phenomenon, most have been limited to using staggered solution schemes, where the diffusion, chemical reaction, mechanical strain, and crack fields are solved for separately. Unfortunately, such approaches introduce numerical errors that can lead to unrealistic predictions. Therefore, a coupled solution, is needed to remove the formulation induced errors and understand this complex phenomenon. To provide a unifying solution framework for corrosion induced cracking in reinforced concrete, a phase field formulation is presented and implemented with FEM algorithms. The governing equations are derived from the system's free energy and Fick's law of diffusion. The proposed formulation was first validated in 1D by comparing the modeling results with the semi-analytical solution approximated via Laurent series to avoid singularities in the complex domain. 2D plane strain solutions to the embedded rebar undergoing corrosion induced cracking with pre-cracks are also presented and compared with the approximated solutions from linear elastic fracture mechanics theory (LEFM). The modeling of crack propagation enabled by the proposed formulation is also presented along with parametric studies to reveal the roles of the fracture toughness and permeability of the concrete on the corrosion induced cracking. A case study was also conducted on H-pile steel with concrete jackets to demonstrate the feasibility of modeling corrosion induced fracture in reinforced concrete structures with complex steel-concrete interfaces.

36 MATERIALS SCIENCE↗