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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 OSTI2018

Processing Parameter Effects on Residual Stress and Mechanical Properties of Selective Laser Melted Ti6Al4V

Selective laser melting (SLM) process is characterized by large temperature gradients resulting in high levels of residual stress within the additively manufactured metallic structure. SLM-processed Ti6Al4V yields a martensitic microstructure due to the rapid solidification and results in a ductility generally lower than a hot working equivalent. Post-process heat treatments can be applied to SLM components to remove in-built residual stress and improve ductility. Residual stress buildup and the mechanical properties of SLM parts can be controlled by varying the SLM process parameters. This investigation studies the effect of layer thickness on residual stress and mechanical properties of SLM Ti6Al4V parts. This is the first-of-its kind study on the effect of varying power and exposure in conjunction with keeping the energy density constant on residual stress and mechanical properties of SLM Ti6Al4V components. It was found that decreasing power and increasing exposure for the same energy density lowered the residual stress and improved the % elongation of SLM Ti6Al4V parts. Increasing layer thickness resulted in lowering the residual stress at the detriment of mechanical properties. The study is based on detailed experimental analysis along with finite element simulation of the process using ABAQUS to understand the underlying physics of the process.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Determination of Residual Stress in Quenched and Cold-Compressed 7050 Aluminum Alloy T-Section Forgings by the Contour Method and Neutron Diffraction

Residual stresses were determined through the thickness of quenched and quenched followed by cold compression 7050 aluminum alloy T-section forgings using the contour method and neutron diffraction. 7050 T-section forgings are used for the manufacture of the connecting joints of wing and fuselage. Inevitably high residual stresses are introduced during the quenching process of 7050 T-section forgings, which could be reduced by cold compression to overcome the effect of residual stress on machining deformation. The longitudinal residual stresses obtained by the two techniques achieved good agreement in both trend and magnitude in both the quenched and quenched followed by cold compression 7050 T-section forgings. The stress-free lattice spacing of Al(311), the Bragg reflection used for the neutron measurements, was obtained from a 5-mm slice using the plane-stress condition, and its variation through the thickness is insignificant in both the quenched specimen and quenched followed by cold compression specimen. A comparison of the residual stresses in the quenched specimen and quenched followed by cold compression specimen showed significant changes in range of residual stresses from (− 304, 262 MPa) induced by quenching process to (− 125, 142 MPa) due to 3% cold compression. The percentage reduction in residual stress in the quenched specimen due to 3% cold compression was (46, 59%).

36 MATERIALS SCIENCE↗
DOE OSTI2019

Residual Stress Asymmetry in Thin Sheets of Double-Sided Shot Peened Aluminum

The local mechanical properties and residual stresses of a double-sided shot-peened aluminum alloy AA7050-T7451 sheet were measured by nanoindentation and simulated by the finite element method (FEM). The variation of the pileup area around the indentation due to residual stresses, as well as changes in hardness as a function of cold working, was assessed. Numerical simulations were conducted to investigate the residual stress profile. When the indentation contact area was corrected to account for pileup induced from residual stresses, the hardness increased about 10% over the range of depths at which compressive residual stresses exist, indicating some strain hardening did occur. The maximum compressive residual stress for the second shot-peened surface is on the order of 10% higher than the first surface; this is ascribed to the sequencing during the peening process, in which the first side peening influenced the stress throughout the part thickness for these thin plate structures. The ability to couple FEM simulations and rapid experimental assessments of residual stresses and hardness allows for future prediction of part thickness effects in double-sided peening processes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A new procedure for implementing the modified inherent strain method with improved accuracy in predicting both residual stress and deformation for laser powder bed fusion

As a metal additive manufacturing (AM) process, laser powder bed fusion (L-PBF) has been widely used to produce parts with complex geometries. The large thermal gradient caused by the fast, intense, and repeated laser scanning induces significant residual deformation and stress to the as-built parts, which increase manufacturing difficulty and geometrical inaccuracy as a result. The modified inherent strain (MIS) method exploiting multiscale process simulations was developed to simulate residual deformation accurately and efficiently. However, the existing procedure of implementing the MIS method is found to give inaccurate residual stress prediction. Here in this work, a new implementation procedure for the MIS method is proposed to improve the simulation accuracy of residual stress without degrading the residual deformation prediction. The new procedure concerns the application of inherent strains to the part-scale layer-by-layer finite element model to obtain residual stress and deformation field. While the existing implementation of the part-scale MIS model involves only mechanical properties at ambient temperature, the new procedure adds one more solution step employing mechanical properties at an elevated temperature determined from the inherent strain extraction step. Both numerical and experimental studies are conducted to validate the proposed new implementation procedure. It shows that by using the new procedure, the MIS-based simulation can predict both residual stress and deformation of as-built L-PBF metal parts with good accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

An a posteriori residual-based spatial discretization error estimator for S N neutron transport

The “residual source estimator”, an implicit residual-based spatial discretization error estimator for S N neutron transport methods, is introduced. The estimator uses an approximation of the residual as a fixed source for an analogous transport problem whose solution is the error estimate, using the same transport operator as the original numerical solution. The complete derivation of the residual source estimator, the approximation of the residual, and higher-order derivatives is included. The performance of the residual source estimator for 0-order DGFEM is tested against reference solutions. For problems with true solutions discontinuous in the first derivative across the singular characteristics, the residual source estimator is generally accurate, precise, and computationally affordable compared to similar estimators. It suffers in problems where solutions are discontinuous, particularly when the discontinuity inflicts significant inaccuracies on the discrete solution; however, compared to other estimators, which suffer similarly, it remains a competitive option.

42 ENGINEERING↗
DOE OSTI2017

Study on the residual stress relaxation in girth-welded steel pipes under bending load using diffraction methods

This research is dedicated to the experimental investigation of the residual stress relaxation in girth-welded pipes due to quasi-static bending loads. Ferritic-pearlitic steel pipes are welded with two passes, resulting in a characteristic residual stress state with high tensile residual stresses at the weld root. Also, four-point bending is applied to generate axial load stress causing changes in the residual stress state. These are determined both on the outer and inner surfaces of the pipes, as well as in the pipe wall, using X-ray and neutron diffraction. Focusing on the effect of tensile load stress, it is revealed that not only the tensile residual stresses are reduced due to exceeding the yield stress, but also the compressive residual stresses for equilibrium reasons. Furthermore, residual stress relaxation occurs both parallel and perpendicular to the applied load stress.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Soil application of high-lignin fermentation byproduct to increase the sustainability of liquid biofuel production from crop residues

When digestates from anaerobic digestion of crop residues are added to soil, a considerable body of information indicates that soil organic carbon (SOC) levels are comparable to those when crop residues are left in the field. This occurs although the amount of digestate added to soil is diminished by digestion and implies that digestion increases the proportion of carbon inputs stabilized as SOC. Here we examine the likelihood and implications of these features being manifested for soil application of high lignin-fermentation byproduct (HLFB) from liquid biofuel production. We show that steady-state SOC levels are much less sensitive to crop residue removal with HLFB return than without it, and provide an example supporting the feasibility of foregoing process energy and coproduct revenue when HLFB is returned to the soil. Informed by this review and analysis, we expect with moderate confidence that long-term SOC levels for soils amended with HLFB from some liquid cellulosic biofuel processes will not be substantially lower than those occurring when crop residues are left in the field. We have high confidence that the economically optimum rate of fertilizer nitrogen (N) application and N 2 O emissions will be lower at most sites for HLFB return to the soil than if crop residues were left in the field. We estimate that the per hectare N demand for processing crop residues to liquid biofuels is about a third of the per hectare demand for crop production, giving rise to an opportunity to use N twice and thereby realize cost savings and environmental benefits. These observations support but do not prove the hypothesis that a ‘win-win’ is possible wherein large amounts of liquid biofuel feedstock can be obtained from crop residues while improving the economics and sustainability of food and feed production. A research agenda aimed at exploring and testing this hypothesis is offered.

09 BIOMASS FUELS↗
DOE OSTI2014

Evolution of titanium residue on the walls of a plasma-etching reactor and its effect on the polysilicon etching rate

The variation in polysilicon plasma etching rates caused by Ti residue on the reactor walls was investigated. The amount of Ti residue was measured using attenuated total reflection Fourier transform infrared spectroscopy with the HgCdTe (MCT) detector installed on the side of the reactor. As the amount of Ti residue increased, the number of fluorine radicals and the polysilicon etching rate increased. However, a maximum limit in the etching rate was observed. A mechanism of rate variation was proposed, whereby F radical consumption on the quartz reactor wall is suppressed by the Ti residue. The authors also investigated a plasma-cleaning method for the removal of Ti residue without using a BCl{sub 3} gas, because the reaction products (e.g., boron oxide) on the reactor walls frequently cause contamination of the product wafers during etching. CH-assisted chlorine cleaning, which is a combination of CHF{sub 3} and Cl{sub 2} plasma treatment, was found to effectively remove Ti residue from the reactor walls. This result shows that CH radicals play an important role in deoxidizing and/or defluorinating Ti residue on the reactor walls.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Experimental Study of Residual Stresses in Hybrid Laser Arc and Submerged Arc-Welded 10-mm-Thick Low-Carbon Steel Plates

Offshore structures are constantly exposed to a multihazard marine environment that threatens their structural integrity. This imposes a high risk for extensive structural failures while various deterioration mechanisms may degrade the available capacity of the structures. Thus, no reliable decisions can be reached regarding design, operation, and survivability of the structures unless a deep comprehension of their fatigue performance is available, including welding-induced residual stresses. In particular, the continuous increase in size of the weldments for the offshore wind industry needs special attention with regard to welding-induced residual stresses, as they can reduce fatigue life, promote distortion, and contribute to stress corrosion cracking. Thus, the current design methods and increased structural dimensions as well as new design and manufacturing methods need to be inspected, understood, and optimized. Related to this, there is a growing need for evaluation of the effect of welding methods with various heat input density distributions. This article deals with the influence of welding method on the welding-induced residual stresses in 10-mm-thick low-carbon structural steel plates. The residual stresses are investigated in hybrid laser-arc welded and submerged arc butt-welded steel plates by means of experimental temperature profile measurements and neutron diffraction measurements and in accordance with existing production procedures. The residual stresses were measured at three different depths in the plates. The goal of the analysis is to gain a comprehensive understanding of the distribution and development of residual stresses in relation to the welding method for better control of the residual stresses and distortion. Furthermore, the repeatability of the neutron diffraction measurements is also investigated and reported in this article.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Comparison of metagenomes from fermentation of various agroindustrial residues suggests a common model of community organization

The liquid residue resulting from various agroindustrial processes is both rich in organic material and an attractive source to produce a variety of chemicals. Using microbial communities to produce chemicals from these liquid residues is an active area of research, but it is unclear how to deploy microbial communities to produce specific products from the different agroindustrial residues. To address this, we fed anaerobic bioreactors one of several agroindustrial residues (carbohydrate-rich lignocellulosic fermentation conversion residue, xylose, dairy manure hydrolysate, ultra-filtered milk permeate, and thin stillage from a starch bioethanol plant) and inoculated them with a microbial community from an acid-phase digester operated at the wastewater treatment plant in Madison, WI, United States. The bioreactors were monitored over a period of months and sampled to assess microbial community composition and extracellular fermentation products. We obtained metagenome assembled genomes (MAGs) from the microbial communities in each bioreactor and performed comparative genomic analyses to identify common microorganisms, as well as any community members that were unique to each reactor. Collectively, we obtained a dataset of 217 non-redundant MAGs from these bioreactors. This metagenome assembled genome dataset was used to evaluate whether a specific microbial ecology model in which medium chain fatty acids (MCFAs) are simultaneously produced from intermediate products (e.g., lactic acid) and carbohydrates could be applicable to all fermentation systems, regardless of the feedstock. MAGs were classified using a multiclass classification machine learning algorithm into three groups, organisms fermenting the carbohydrates to intermediate products, organisms utilizing the intermediate products to produce MCFAs, and organisms producing MCFAs directly from carbohydrates. This analysis revealed common biological functions among the microbial communities in different bioreactors, and although different microorganisms were enriched depending on the agroindustrial residue tested, the results supported the conclusion that the microbial ecology model tested was appropriate to explain the MCFA production potential from all agricultural residues.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Study on the Impacts of Capillary Number and Initial Water Saturation on the Residual Gas Distribution by NMR

The determination of microscopic residual gas distribution is beneficial for exploiting reservoirs to their maximum potential. In this work, both forced and spontaneous imbibition (waterflooding) experiments were performed on a high-pressure displacement experimental setup, which was integrated with nuclear magnetic resonance (NMR) to reveal the impacts of capillary number ( Ca ) and initial water saturation ( S wi ) on the residual gas distribution over four magnitudes of injection rates (Q = 0.001, 0.01, 0.1 and 1 mL/min), expressed as Ca (log Ca = –8.68, –7.68, –6.68 and –5.68), and three different S wi ( S wi = 0%, 39.34% and 62.98%). The NMR amplitude is dependent on pore volumes while the NMR transverse relaxation time ( T 2 ) spectrum reflects the characteristics of pore size distribution, which is determined based on a mercury injection (MI) experiment. Using this method, the residual gas distribution was quantified by comparing the T 2 spectrum of the sample measured after imbibition with the sample fully saturated by brine before imbibition. The results showed that capillary trapping efficiency increased with increasing S wi , and above 90% of residual gas existed in pores larger than 1 μm in the spontaneous imbibition experiments. The residual gas was trapped in pores by different capillary trapping mechanisms under different Ca , leading to the difference of residual gas distribution. The flow channels were mainly composed of micropores (pore radius, r < 1 μm) and mesopores ( r = 1–10 μm) at log Ca = –8.68 and –7.68, while of mesopores and macropores (r > 10 μm) at logCa = –5.68. At both S wi = 0% and 39.34%, residual gas distribution in macropores significantly decreased while that in micropores slightly increased with log Ca increasing to –6.68 and –5.68, respectively.

02 PETROLEUM↗
NASA NTRS2023

Emission Factors for Crop Residue and Prescribed Fires in the Eastern US during FIREX-AQ

Agricultural and prescribed burning activities emit large amounts of trace gases and aerosols on regional to global scales. We present a compilation of emission factors (EFs) and emission ratios (ERs) from the eastern portion of the Fire Influence on Regional to Global Environments and Air Quality (FIREX-AQ) campaign in 2019 in the United States, which sampled burning of crop residues and other prescribed fire fuels. FIREX-AQ provided comprehensive chemical characterization of 53 crop residue and 22 prescribed fires. Crop residues burned at different modified combustion efficiencies (MCE), with corn residue burning at higher MCE than other fuel types. Prescribed fires burned at lower MCE (<0.90) which is typical, while grasslands burned at lower MCE (0.90) than normally observed due to moist, green, growing season fuels. Most non-methane volatile organic compounds (NMVOCs) were significantly anticorrelated with MCE except for ethanol and NMVOCs that were measured with less certainty. We identified 23 species where crop residue fires differed by more than 50% from prescribed fires at the same MCE. Crop residue EFs were greater for species related to agricultural chemical use and fuel composition as well as oxygenated NMVOCs possibly due to the presence of metals such as potassium. Prescribed EFs were greater for monoterpenes (5×). FIREX-AQ crop residue average EFs generally agreed with the previous agricultural fire study in the US but had large disagreements with global compilations. FIREX-AQ observations show the importance of regionally-specific and fuel-specific EFs as first steps to reduce uncertainty in modeling the air quality impacts of fire emissions.

air quality↗
NASA NTRS2024

Exploring the Role of Type-II Residual Stresses in A Laser Powder Bed Fusion Nickel-Based Superalloy Using Measurement and Modeling

Far-field high-energy X-ray diffraction microscopy (ff-HEDM) and the crystal plasticity finite element method (CPFEM) are used to investigate the role of grain-scale (Type-II) residual stresses on the fatigue life of additively manufactured (AM) Inconel alloy 625 (IN-625). Grain-averaged orientations, centroids, and residual elastic strain tensors from ff-HEDM data are used to instantiate a crystal plasticity model to simulate the effect of residual stresses at the grain scale. Simulation results indicate that the presence of tensile residual strains increase stress localization and heterogeneity within grains, triggering an earlier onset of plasticity. A microscale fatigue indicator parameter (FIP) is computed to model the impact of these residual strains on the cycles to fatigue crack nucleation. The crack nucleation model, based on the computed FIPs, predicts a significant reduction in the number of cycles for fatigue crack nucleation for mid- and high-cycle fatigue due to the residual strain induced localization, while the residual strains have minimal impact on low-cycle fatigue life.

Inconel↗
DOE OSTI2017

Numerical and neutron diffraction measurement of residual stress distribution in dissimilar weld

In this study, a model considering an asymmetric power heat distribution, temperature-dependent material properties, strain hardening and phase transformation was developed to predict temperature field and residual stress distribution in GTA dissimilar weld between austenitic stainless steel (304) and low carbon steel (1018). The effect of martensite formation on longitudinal and transverse residual stress distributions were investigated using both FE model and neutron diffraction measurement. The results indicate that martensitic phase has a significant influence on both residual stress components, i.e., transverse and longitudinal, and it not only can change the distribution shape of residual stress near the weld center line but, also, can alter the peak value of the residual stresses. The calculated temperature and weld zone profile were in agreement with the experimental results. Favorable general agreement was also found between the calculated residual stress distribution and residual stress measurements by the neutron diffraction method.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Measurement of Residual Strain in the Cylinder Bridge of High-Pressure Die Cast A383 Engine Blocks Using Neutron Diffraction

This article describes the use of neutron diffraction to measure residual strains in high-pressure die cast aluminum alloy engine blocks. High-pressure die casting is widely used to manufacture aluminum alloy components for automobile applications such as engine blocks. Thermal gradients during this process can generate residual strain and stresses and may cause premature failure during service. Neutron diffraction can be used to measure the residual stress distributions deep inside large castings, as neutrons have much larger penetrating power than X-rays. In this work, neutron diffraction was used to measure the residual strain (in the axial and hoop directions) in the cylinder bridge region of high-pressure die cast A383 engine blocks in as-cast and heat-treated conditions. The results suggest that the residual strain in the cylinder bridge is tensile in both the axial and hoop components for both as-cast and heat-treated engines. The residual strain in hoop direction is higher than the strain in axial direction. Residual strain in axial and hoop directions is relaxed after heat treatment.

Liu, Tao↗
DOE OSTI2021

Consumable development to tailor residual stress in parts fabricated using directed energy deposition processes

Distortion and residual stresses are major challenges that limit the ability to fabricate large scale structures using Additive Manufacturing (AM). Researchers worldwide are evaluating techniques to induce compressive residual stress in the parts via intermittent rolling. While reasonable success has been documented, the idea of lowering the martensite start temperature to induce compressive stresses has not been evaluated in the context of AM, despite demonstrated success by the welding community. This study validates the hypothesis that, by a proper selection of materials and process parameters, one may effectively reduce distortion and induce a compressive residual stress in AM parts. Using neutron diffraction to measure residual stresses in parts, we demonstrate that, in addition to selection of the correct materials, the inter pass temperature plays a major role in controlling the residual stress evolution. The observations relating to the residual stresses are rationalized based on a microstructural evolution in these samples. Based on this preliminary study, a strategy to fabricate large structures with minimal distortion and residual stress is outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2017

An improved prediction of residual stresses and distortion in additive manufacturing

In laser assisted additive manufacturing (AM) an accurate estimation of residual stresses and distortion is necessary to achieve dimensional accuracy and prevent premature fatigue failure, delamination and buckling of components. Since many process variables affect AM, experimental measurements of residual stresses and distortion are time consuming and expensive. Numerical thermo-mechanical models can be used for their estimation, but the quality of calculations depends critically on the accurate transient temperature field which affects both the residual stresses and distortion. Here in this study, a well-tested, three-dimensional, transient heat transfer and fluid flow model is used to accurately calculate transient temperature field for the residual stress and distortion modeling. The calculated residual stress distributions are compared with independent experimental results. It is shown that the residual stresses can be significantly minimized by reducing the layer thickness during AM. Inconel 718 components are found to be more susceptible to delamination than Ti-6Al-4V parts because they encounter higher residual stresses compared to their yield strength.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Tri-peptide reference structures for the calculation of relative solvent accessible surface area in protein amino acid residues

Relative amino acid residue solvent accessibility values allow the quantitative comparison of atomic solvent-accessible surface areas in different residue types and physical environments in proteins and in protein structural alignments. Geometry-optimised tri-peptide structures in extended solvent-exposed reference conformations have been obtained for 43 amino acid residue types at a high level of quantum chemical theory. Significant increases in side-chain solvent accessibility, offset by reductions in main-chain atom solvent exposure, were observed for standard residue types in partially geometry-optimised structures when compared to non-minimised models built from identical sets of proper dihedral angles abstracted from the literature. Optimisation of proper dihedral angles led most notably to marked increases of up to 54% in proline main-chain atom solvent accessibility compared to literature values. Similar effects were observed for fully-optimised tri-peptides in implicit solvent. The relief of internal strain energy was associated with systematic variation in N, C α and C β atom solvent accessibility across all standard residue types. The results underline the importance of optimisation of ‘hard’ degrees of freedom (bond lengths and valence bond angles) and improper dihedral angle values from force field or other context-independent reference values, and impact on the use of standardised fixed internal co-ordinate geometry in sampling approaches to the determination of absolute values of protein amino acid residue solvent accessibility. Finally, quantum chemical methods provide a useful and accurate alternative to molecular mechanics methods to perform energy minimisation of peptides containing non-standard (chemically modified) amino acid residues frequently present in experimental protein structure data sets, for which force field parameters may not be available. Reference tri-peptide atomic co-ordinate sets including hydrogen atoms are made freely available.

59 BASIC BIOLOGICAL SCIENCES↗