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Results for “RESIDUAL STRESSES”

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 OSTI2019

Photoluminescence Spectroscopy to Determine Residual Stresses in Glass-to-Metal Seals

In components with two materials, such as glass-to-metal (GtM) seals, residual stress can reduce long-term reliability. Therefore, it is important to be able to accurately measure residual stress within these components. The residual stress can be from a large strain due to the mismatch of thermo-physical response of the two materials or a small strain due to stress and/or structural relaxation. Both modeling and experimental measurements were conducted on multiple GtM seals constructed with CGI 930 glass with purposely added alumina particles. The alumina particles have an established Cr fluorescence pattern and the shift in position of these peaks can accurately measure the strain of the alumina crystals. Photoluminescence spectroscopy (PLS) technique was utilized due to its non-destructive nature and high spatial resolution. PLS scans of these components were analyzed and compared to the models developed previously.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Residual stress in high modulus carbon fibers

The modulus and residual strain in carbon fibers are measured by successively electrochemically milling away the fiber surface. Electrochemical etching is found to remove the carbon fiber surface very uniformly, in contrast to air and wet oxidation. The precision of fiber diameter measurements is improved by using a laser diffraction technique instead of optical methods. More precise diameter measurements reveal that past correlations of diameter and fiber modulus are largely measurement artifact. The moduli of most carbon fibers decrease after the outer layers of the fibers are removed. Owing to experimental difficulties, the moduli and strengths of the fibers at their centers are not determined, and moduli are estimated on the basis of microstructure. The calculated residual stresses are found to be insensitive to these moduli estimates as well as the exact form of regression equation used to describe the moduli and residual strain distributions. Axial compressive residual stresses are found to be very high for some higher modulus carbon fibers. It is pointed out that the compressive stress makes the fibers insensitive to surface flaws when loaded in tension but it may initiate failure by buckling when loaded in compression.

Chen, K. J.↗
DOE OSTI2019

Evaluation of a thermomechanical model for prediction of residual stress during laser powder bed fusion of Ti-6Al-4V

The build-up of residual stresses in a part during laser powder bed fusion provides a significant limitation to the adoption of this process. These residuals stresses may cause a part to fail during a build or fall outside the specified tolerances after fabrication. In the present work a thermomechanical model is used to simulate the build process and calculate the residual stress state for Ti–6Al–4V specimens built with continuous and island scan strategies. A layer agglomeration, or lumping, approach is used to speed up the computations. A material model is developed to naturally capture the strain-rate dependence and annealing behavior of Ti–6Al–4V at elevated temperatures. Conclusions from the thermomechanical simulations showed good agreement with synchrotron X-ray diffraction measurements used to determine the residual elastic strains in these parts. Yet, the experimental measurements showed higher residual strains for the specimen built with an island scan strategy; a trend not fully captured by the simulations. Parameter studies were performed to fully understand the advantages and limitations of the current simulation methodology. Reasons for both the computational and experimental findings are discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Residual stresses in angleplied laminates and their effects on laminate behavior

Evidence of the presence of lamination residual stresses in angleplied laminates were transply cracks and warpage of unsymmetric laminates which occur prior to application of any mechanical load. Lamination residual strains were measured using the embedded strain gage technique. These strains result from the temperature differences between cure and room temperature and vary linearly within this temperature range. Lamination residual stresses were usually present in angleplied fiber composites laminates; they were also present in unidirectional hybrids and superhybrids. For specific applications, the magnitudes of lamination residual stresses were determined and evaluated relative to the anticipated applied stresses. Particular attention was given to cyclic thermal loadings in applications where the thermal cycling takes place over a wide temperature range.

Chamis, C. C.↗
DOE OSTI2017

Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling down were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Simplified micromechanical equations for thermal residual stress analysis of coated fiber composites

The fabrication of metal matrix composites poses unique problems to the materials engineer. The large thermal expansion coefficient mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix interface which could lead to premature matrix cracking during cooldown. Fiber coating could be used to reduce thermal residual stresses. A simple closed-form analysis, based on a three-phase composite cylinder model, was developed to calculate thermal residual stresses in a fiber/interface/matrix system. Guidelines, in the form of simple equations, for the selection of appropriate material properties of the fiber coating, were also derived to minimize thermal residual stresses in the matrix during fabrication.

Naik, Rajiv A.↗
DOE OSTI2023

MOOSE Optimization Module Overview: Application to Residual Stress Inversion in Nuclear Fuel Plates

Manufacturing methods, material selections and unique plate geometries used in low enriched uranium plate fuels for the High Performance Research Reactor (HPRR) have led to concerns about the residual stresses effect on bond strength of the fuel/cladding interfaces and overall fuel performance under irradiation. The current HPRR plate fuel test program performed residual stress calculations using the contour method with experimental displacement data obtained by incrementally cutting the plate fuel. In this work, we use a gradient based inverse optimization module developed within the MOOSE framework to estimate normal and shear residual stresses within the plate fuels using displacement data taken from a cut placed in the HPRR fuel plate. These results are verified against residual stress calculations obtained from the contour method. The inversion protocol used in this work utilizes two meshes to separately discretize the physics and parameter space. This allows a fine mesh to be used to fully resolve the physics and geometry of the forward problem. A coarser mesh is used to resolve the parameter space with spatially varying mesh density determined from a sensitivity analysis. The adaptive resolution of the parameter space essentially has the effect of regularization as it is designed to achieve the bias-variance tradeoff.

42 ENGINEERING↗
DOE OSTI2019

Neutron Residual Stress Mapping of Repaired Spent Nuclear Fuel Welded Stainless-Steel Canisters

Stress corrosion cracking (SCC) caused by atmospheric deposition and deliquescence of aggressive compounds such as chloride-containing salts or oxidized sulfur species may pose a potential issue to the extended service life of spent nuclear fuel (SNF) storage canisters. When a chemically susceptible material is exposed to a hostile environment (e.g., coastal salt air) for a sufficient length of time, SCC may occur at locations on the canister which have undergone high tensile residual stress. These locations are often found in weld zones and the heat-affected zones (HAZ) of welded joints. Ideally, these cracks could be repaired by traditional fusion welding techniques, but the highly localized heat input of the repair welding may introduce additional high tensile residual stress and could increase the risk for future SCCs. This paper presents the results of neutron residual stress mapping of as-welded and repaired stainless steel specimens. The as-welded specimens were provided by Sandia National Laboratories from a canister mock-up manufactured using procedures similar to those used for actual canister production. ASME-qualified gas-tungsten arc welding (GTAW) was used to repair the specimens, and post-repair residual stresses were measured using neutron diffraction at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR). As-welded and repaired specimen residual stress distributions are evaluated and compared.

Chatzidakis, Stylianos↗
DOE OSTI2023

3D mapping of residual stresses in growing grains of partially recrystallized Gum Metal

The crystallographic orientations and residual stresses within recrystallizing grains in partially recrystallized beta titanium-Gum Metal-were examined non-destructively in 3D using synchrotron Differential Aperture X-ray Microscopy. Contrary to common assumptions, significant local stresses and stress variations are observed within the recrystallizing grains. The results reveal that the development of these local residual stresses depends on the plastic deformation mode and material's elastic constants, rather than grain properties such as size and orientation, or even the material's yield stress. This work provides insights valuable for the design of advanced materials with heterogeneous microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Residual-stress-induced grain growth of twinned grains and its effect on formability of magnesium alloy sheet at room temperature

A magnesium alloy sheet was subjected to in-plane compression along with a vertical load to avoid buckling during compression. Pre-compressed specimens machined from the sheet were annealed at different temperatures and the changes in microstructure and texture were observed using electron back scattered diffraction (EBSD). Twinned grains preferentially grew during annealing at 300 °C, so that a strong texture with the < 0001 > direction parallel to the transverse direction developed. EBSD analysis confirmed that the friction caused by the vertical load induced inhomogeneous distribution of residual stress, which acted as an additional driving force for preferential grain growth of twinned grain during annealing. The annealed specimen showed excellent formability. - Highlights: • A magnesium alloy sheet subjected to in-plane compression under a vertical load • The vertical load induced inhomogeneous distribution of the residual stress. • The residual stress acted as an additional driving force for grain growth. • The annealed specimen with strong non-basal texture showed excellent formability.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Residual stresses in continuous graphite fiber Al metal matrix composites

The residual stresses in graphite fiber reinforced aluminum (Gr/Al) composites with various thermal histories are measured using X-ray diffraction (XRD) methods. The XRD stress analysis is based on the determination of lattice strains by precise measurements of the interplanar spacings in different directions of the sample. The sample is a plate consisting of two-ply P 100 Gr/Al 6061 precursor wires and Al 6061 overlayers. Prior to XRD measurement, the 6061 overlayers are electrochemically removed. In order to calibrate the relationship between stress magnitude and lattice spacing shift, samples of Al 6061 are loaded at varying stress levels in a three-point bend fixture, while the stresses are simultaneously determined by XRD and surface-attached strain gages. The stresses determined by XRD closely match those determined by the strain gages. Using these calibrations, the longitudinal residual stresses of P 100 Gr/Al 6061 composites are measured for various heat treatments, and the results are presented.

Park, Hun Sub↗
DOE OSTI2025

Resonance ultrasound prediction of residual stress within a hybrid layer for additively manufactured samples

Hybrid additive manufacturing (AM) involves secondary processes or energy sources to alter specified locations within the build volume. Each hybrid step can refine the grain size, increase dislocation density, or modify residual stresses. Typically, the changes in mechanical properties are not confined within a single layer but have a compounding effect on preceding layers. Existing methods of measuring AM residual stress are limited in terms of their sensitivity, or they are destructive measurements. We propose using resonant ultrasound spectroscopy (RUS) to measure the residual stress in hybrid-AM components noninvasively, based on changes to the resonances, compared to a stress-free component. In this paper, we use finite element models to simulate residual stress in hybrid-AM components and to examine the sensitivity of RUS measurements in terms of frequency shifts and mode shapes with respect to single hybrid layers. Then, the RUS results are used to predict stress for a layer at a known location with unknown stress. Here, the approach highlights the capabilities of RUS to address an AM characterization challenge.

36 MATERIALS SCIENCE↗
NASA NTRS1996

Optimization of residual stresses in MMC's through the variation of interfacial layer architectures and processing parameters

The objective of this work was the development of efficient, user-friendly computer codes for optimizing fabrication-induced residual stresses in metal matrix composites through the use of homogeneous and heterogeneous interfacial layer architectures and processing parameter variation. To satisfy this objective, three major computer codes have been developed and delivered to the NASA-Lewis Research Center, namely MCCM, OPTCOMP, and OPTCOMP2. MCCM is a general research-oriented code for investigating the effects of microstructural details, such as layered morphology of SCS-6 SiC fibers and multiple homogeneous interfacial layers, on the inelastic response of unidirectional metal matrix composites under axisymmetric thermomechanical loading. OPTCOMP and OPTCOMP2 combine the major analysis module resident in MCCM with a commercially-available optimization algorithm and are driven by user-friendly interfaces which facilitate input data construction and program execution. OPTCOMP enables the user to identify those dimensions, geometric arrangements and thermoelastoplastic properties of homogeneous interfacial layers that minimize thermal residual stresses for the specified set of constraints. OPTCOMP2 provides additional flexibility in the residual stress optimization through variation of the processing parameters (time, temperature, external pressure and axial load) as well as the microstructure of the interfacial region which is treated as a heterogeneous two-phase composite. Overviews of the capabilities of these codes are provided together with a summary of results that addresses the effects of various microstructural details of the fiber, interfacial layers and matrix region on the optimization of fabrication-induced residual stresses in metal matrix composites.

Pindera, Marek-Jerzy↗
DOE OSTI2023

MODELS FOR ESTIMATING THE AUTOFRETTAGE PRESSURE AND RESIDUAL STRESSES IN WALLS OF TYPE 2 PRESSURE VESSELS

Autofrettage is a manufacturing process used during fabrication of Type 2 pressure vessels designed for usage at high pressures to enhance the fatigue life. The process locks high compressive residual stresses in the vessel’s liner wall that reduce the maximum and the mean stress during service loading. To achieve a consistent residual stress profile across the wall of the vessel, the choice of autofrettage pressure is critical. Several finite element analyses runs were conducted to estimate the correct autofrettage pressure that is a function of the yield strength of the liner material, the wall thickness, and the outside diameter of the liner for a wrap thickness of 17.06 mm (48 wire layers). From the finite element analyses results, models were developed to estimate the correct autofrettage pressure and the residual stress distribution across the liner wall as a function of the yield strength of the liner material, the wall thickness, and the outside diameter of the liner.

08 HYDROGEN↗
DOE OSTI2018

Residual stress evaluation of components produced via direct metal laser sintering

Direct metal laser sintering is an additive manufacturing process which is capable of fabricating three-dimensional components using a laser energy source and metal powder particles. Despite the numerous benefits offered by this technology, the process maturity is low with respect to traditional subtractive manufacturing methods. Relationships between key processing parameters and final part properties are generally lacking and require further development. In this study, residual stresses were evaluated as a function of key process variables. The variables evaluated included laser scan strategy and build plate preheat temperature. Residual stresses were measured experimentally via neutron diffraction and computationally via finite element analysis. Good agreement was shown between the experimental and computational results. Results showed variations in the residual stress profile as a function of laser scan strategy. Compressive stresses were dominant along the build height (z) direction, and tensile stresses were dominant in the x and y directions. Build plate preheating was shown to be an effective method for alleviating residual stress due to the reduction in thermal gradient.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

X-Ray Diffraction Measurements of Residual Stress in a Cold Sprayed Ni Coating

X-ray diffraction (XRD) was used to investigate the residual stress in a cold sprayed Ni coating which failed to form a bimetallic joint with NASA HR-1. The objective was to apply pure Ni by cold spray as a diffusion barrier between the Ni-based alloy NASA HR-1 and the Cu-based GRCop-42 for a thrust cell assembly. After additive manufacturing of the GRCop-42 cylinder, the commercially pure Ni coating was cold sprayed onto the cylinder. It was intended to have NASA HR-1 applied directly onto the Ni coating by Directed Energy Deposition (DED), however the bond failed during the first layer of DED. Residual stress measurements were collected via the Sin²ψ method in three equally spaced locations on the top surface of the Ni coating in both as-cold sprayed and heat-treated conditions. The results revealed both compressive and tension stresses on the as-cold sprayed sample and compressive stresses in the heat-treated sample. The results were illuminated when plotted at their respective positions and with their respective orientation angles around a circle. This showed rotational symmetry in the residual stress measurements, which correlated to the processing method used during application of the Ni coating.

Laura Wilson↗
DOE OSTI2019

Methods of Measuring Residual Stresses in Additively Manufactured 316L Stainless Steel

The microstructure of AM 316L stainless steel Is different from steel manufactured using conventional methods e.g. casting and forging. Data on the effects of residual stresses in the structural integrity and importance of AM parts (fatigue behavior) must be quantified. Evaluate different methods and identify a viable process for determining residual stresses in 316L stainless steel. Next step is to conduct measurements of residual stresses of samples fabricated by different manufacturers.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

From cells to laminate: probing and modeling residual stress evolution in thin silicon photovoltaic modules using synchrotron X-ray micro-diffraction experiments and finite element simulations

Fracture of silicon crystalline solar cells has recently been observed in increasing percentages especially in solar photovoltaic (PV) modules involving thinner silicon solar cells (<200 μm). Many failures due to fracture have been reported from the field because of environmental loading (snow, wind, etc.) as well as mishandling of the solar PV modules (during installation, maintenance, etc.). However, a significantly higher number of failures have also been reported during module encapsulation (lamination) indicating high residual stress in the modules and thus more prone to cell cracking. Here in this paper we report through the use of synchrotron X-ray submicron diffraction coupled with physics-based finite element modeling, the complete residual stress evolution in mono-crystalline silicon solar cells during PV module integration process. For the first time, we unravel the reason for the high stress and cracking of silicon cells near soldered inter-connects. Our experiments revealed a significant increase of residual stress in the silicon cell near the solder joint after lamination. Moreover, our finite element simulations show that this increase of stress during lamination is a result of highly localized bending of the cell near the soldered inter-connects. Further, the synchrotron X-ray submicron diffraction has proven to be a very effective way to quantitatively probe mechanical stress in encapsulated silicon solar cells. Thus, this technique has ultimately enabled these findings leading to the enlightening of the role of soldering and encapsulation processes on the cell residual stress. This model can be further used to suggest methodologies that could lead to lower stress in encapsulated silicon solar cells, which are the subjects of our continued investigations.

14 SOLAR ENERGY↗