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Typical High Temperature Applications High Temperature Applications Demand High Performance Materials: 1) Complex Thermomechanical Loading; 2) Complex Material response requires Time-Dependent/Hereditary Models: Viscoelastic/Viscoplastic; and 3) Comprehensive Characterization (Tensile, Creep, Relaxation) for a variety of material systems.
The integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC (Micromechanics Analysis Code/Generalized Method of Cells) multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button-sized disk-shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300 degrees Centigrade to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.
Cyclic Damage Accumulation (CDA) computer program performs high-temperature, low-cycle-fatigue life prediction for materials analysis. Designed to account for effects on creep-fatigue life of complex loadings involving such factors as thermomechanical fatigue, hold periods, wave-shapes, mean stresses, multiaxiality, cumulative damage, coatings, and environmental attack. Several features practical for application to actual component analysis using modern finite-element or boundary-element methods. Although developed for use in predicting crack-initiation lifetimes of gas-turbine-engine materials, also applied to other materials as well. Written in FORTRAN 77.
The effect of varied thermomechanical processing on discontinuous precipitation (DP) in U-10Mo was investigated, with specific emphasis on understanding the role of grain boundary misorientation in DP. Varied prior homogenization heat treatment and thermomechanical processing resulted in differences in both the fraction of DP and the colony width, and was attributed to variations in the grain boundary misorientation distribution. Regardless of the degree of DP-based transformation, extensive growth of DP colonies was dominant on 30°–45° misorientation boundaries. Interestingly, misorientation histograms of the deformed and annealed specimens suggest the processing steps involved may have inhibited DP colony growth along a small fraction of these high angle boundaries. Large-area electron backscatter diffraction montages coupled with high resolution mapping suggest symmetric {110}-type interfaces may be important considerations for mitigating extensive DP growth in this alloy system.
The study of x-ray induced rapid heating and the resulting material responses - (thermomechanical shock (TMS) and thermo-structural response (TSR)) - is important to our understanding of material behavior in extreme environments. A series of high conversion efficiency (XRCE) x-ray sources have been developed for the NIF laser facility ranging in fluence and spectral content. In conjunction with source development, we have developed a new XTRRA (X-ray Transport and Radiation Response Analysis) test cassette to hold a set of samples, each at equal distance from target chamber center (TCC) where the x-ray source is placed. Design and performance details of the x-ray sources is discussed elsewhere. Here, we describe the development and use of this TMS XTRRA test cassette. The XTRRA test cassette is a snout mounted on a NIF Diagnostic Instrument Manipulator (DIM) designed to position six samples equidistant from the x-ray source to assure uniform irradiation of all samples. Photon Displacement interferometry (PDI) is used to measure the displacement of the rear surface of each sample resulting from x-ray exposure on the front of the sample. This will help determine the x-ray generated impulse on the sample. The samples are retrieved from the snout after the shot for inspection and post-shot analysis including the measurement of sample ablated mass and engineering tests examining changes in the material structure. The data from experiments are compared to predictions from LLNL’s ASC codes and used to inform models implemented in these codes. Thus, XRCE x-ray sources with the XTRRA snout at the National Ignition Facility (NIF) laser at the Lawrence Livermore National Laboratory provide the ability to expose a broad range of material samples directly to high x-ray fluence, measure shock transits, and recover the sample for further analysis post-shot.
A computational capability for predicting the nonlinear thermomechanical structural response of fiber-reinforced superalloy (FRS) turbine blades is described. This capability is embedded in a special purpose computer code (COBSTRAN) developed at the NASA Lewis Research Center. Special features of this computational capability include accounting for: fiber/matrix reaction, nonlinear and anisotropic material behavior, complex stress distribution due to local and global heterogeneity, and residual stresses due to initial fabrication and/or inelastic behavior during subsequent missions. Numerical results are presented from analyses of a hypothetical FRS turbine blade subjected to a fabrication process and subsequent mission cycle. The results demonstrate the capabilities of this computational tool to; predict local stress/strain response and capture trends of local nonlinear and anisotropic material behavior, relate the effects of this local behavior to the global response of a multilayered fiber-composite turbine blade, and trace material history from fabrication through successive missions.
Interaction of mechanical and thermal stresses with the flaws and microcracks within the ceramic region of metal-ceramic dental crowns can result in catastrophic or delayed failure of these restorations. The objective of this study was to determine the combined influence of induced functional stresses and pre-existing flaws and microcracks on the time-dependent probability of failure of a metal-ceramic molar crown. A three-dimensional finite element model of a porcelain fused-to-metal (PFM) molar crown was developed using the ANSYS finite element program. The crown consisted of a body porcelain, opaque porcelain, and a metal substrate. The model had a 300 Newton load applied perpendicular to one cusp, a load of 30ON applied at 30 degrees from the perpendicular load case, directed toward the center, and a 600 Newton vertical load. Ceramic specimens were subjected to a biaxial flexure test and the load-to-failure of each specimen was measured. The results of the finite element stress analysis and the flexure tests were incorporated in the NASA developed CARES/LIFE program to determine the Weibull and fatigue parameters and time-dependent fracture reliability of the PFM crown. CARES/LIFE calculates the time-dependent reliability of monolithic ceramic components subjected to thermomechanical and/Or proof test loading. This program is an extension of the CARES (Ceramics Analysis and Reliability Evaluation of Structures) computer program.
Products made from advanced ceramics show great promise for revolutionizing aerospace and terrestrial propulsion, and power generation. However, ceramic components are difficult to design because brittle materials in general have widely varying strength values. The CAPES/Life software eases this task by providing a tool to optimize the design and manufacture of brittle material components using probabilistic reliability analysis techniques. Probabilistic component design involves predicting the probability of failure for a thermomechanically loaded component from specimen rupture data. Typically, these experiments are performed using many simple geometry flexural or tensile test specimens. A static, dynamic, or cyclic load is applied to each specimen until fracture. Statistical strength and SCG (fatigue) parameters are then determined from these data. Using these parameters and the results obtained from a finite element analysis, the time-dependent reliability for a complex component geometry and loading is then predicted. Appropriate design changes are made until an acceptable probability of failure has been reached.
Intelligent materials are those that exhibit coupling between their electromagnetic response and their thermomechanical response. This coupling allows smart materials to react mechanically (e.g., an induced displacement) to applied electrical or magnetic fields (for instance). These materials find many important applications in sensors, actuators, and transducers. Recently interest has arisen in the development of smart composites that are formed via the combination of two or more phases, one or more of which is a smart material. To design with and utilize smart composites, designers need theories that predict the coupled smart behavior of these materials from the electromagnetothermoelastic properties of the individual phases. The micromechanics model known as the generalized method of cells (GMC) has recently been extended to provide this important capability. This coupled electromagnetothermoelastic theory has recently been incorporated within NASA Glenn Research Center's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). This software package is user friendly and has many additional features that render it useful as a design and analysis tool for composite materials in general, and with its new capabilities, for smart composites as well.
Foil enclosure configurations of 10 variations were fabricated and evaluated. A discussion of the thermal protection system panel design includes: (1) description of 3DSX/foil concept, (2) design environment, (3) material selection, (4) fabrication enclosure, (5) structural design, (6) thermal sizing, and (7) weight analysis. The structural design study includes foil evaluation, venting pressure loads, thermomechanical behavior, and enclosure venting (burst) pressure tests. Results of experimental demonstrations of performance and reuse capabilities are given for both thermal and acoustic testing.
A variationally consistent theory is developed in order to derive the governing equations of anisotropic thin-walled beams with closed sections subjected to axial load, torsion, bending and hygrothermal loads. The theory is based on an asymptotical analysis of two-dimensional shell theory. Closed-form expressions for the beam stiffness coefficients, equivalent hygrothermal loads, stress and displacement fields are provided. The influence of material anisotropy and hygrothermal coefficients on the displacement field is identified. The analysis is applied to predict the response of composite beams under thermomechanical loading.
A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.
Semicrystalline polymers have a degree of crystallinity that depends on chain structure and crystallization conditions. Thermomechanical properties are influenced by the degree of crystallinity and crystalline morphology. A common method used to understand crystalline content, crystal and amorphous layer thickness, and layer thickness distributions, is X-ray scattering (XS). This report uses XS to first investigate crystalline orientation in high density polyethylene (HDPE) samples. Then, a single orientation is analyzed via XS in a temperature study to investigate crystalline behavior under changing temperatures. Lastly, block copolymer filaments extruded at varying speeds are analyzed. The X-ray data are used to gain a baseline understanding of crystalline behavior in these unique filaments.
To maximize thermal efficiency, the National Renewable Energy Laboratory (NREL) has proposed a light-trapping cavity-planar receiver design intended to capture energy from reradiating surfaces. This system implements a macroscale light trapping mechanism induced by panels with triangular channels, this mechanism allows for elevated temperatures on the receiver panels and in turn the temperature of the HTF; using this design coupled with the implementation of a fluidized particle flow as the HTF, it can be expected for some components to reach a peak working temperature of nearly 1000 degrees C cyclically throughout each day-night cycle. While these temperatures correlate to higher efficiency of the CSP tower they also demand intense thermomechanical properties from the materials used to make the receiver panels. In this analysis, we will list our assumptions to provide clarity on the significance of our calculation. This cost analysis will be conducted using a combination of both case study data and surveying industry to determine costs that are relevant to the current market trends. This analysis represents an early attempt to establish the Capital Expenditures required for a CSP tower of such design to determine the feasibility of implementing such a system in the industry.
Over the course of 60 years of shape memory alloy research and development, the properties of these alloys have been measured using various testing methods, which are often customized by the organization performing the test. However, commercial adoption of shape memory alloys in aeronautic actuator applications requires reducing property uncertainty through standardizing test methods. Historically, differential scanning calorimetry (DSC) has been used to measure transformation temperatures under stress-free conditions. This testing method is well established, and tests are run under the applicable standard, ASTM F2004-17: Standard Test Method for Transformation Temperature of Nickel-Titanium Alloys by Thermal Analysis. Two other test methods for measuring strains and transformation temperatures under constant load or free recovery after prestraining have only recently been standardized—ASTM E3097: Standard Test Method for Mechanical Uniaxial Constant Force Thermal Cycling of SMAs (UCFTC) and ASTM E3098: Standard Test Method for Mechanical Uniaxial Pre-Strain and Thermal Free Recovery of SMAs (UPFR). These standards represent a critical step forward in producing reliable material property data for the use of these alloys in aeronautics and other commercial areas. However, no standard programs or software packages were previously available for postprocessing UCFTC- and UPFR-type test data to extract property data. Each organization that performed the testing analyzed data using its own custom manual methods, such as using a plot and a straight edge, spreadsheet plotting methods, or custom code routines, to extract the required values for strains, stresses, and transformation temperatures. SMAnalytics represents the first publicly available uniform software package for processing data generated using the DSC, UCFTC, and UPFR test methods, as well as many modifications of these methods, including loading in martensite versus austenite and performing multiple thermal cycles at stress. In doing so, it provides a tool for reducing potential error or variability in the measured values due to the precision of the technique used and person-to-person variability. It is also expected that this automated data-parsing tool can accelerate the data analysis phase of the test campaign, especially for large data files. This User’s Manual describes how the SMAnalytics software works and the method for its use.
A simplified inelastic analysis computer program was developed for predicting the stress-strain history of a thermomechanically cycled structure from an elastic solution. The program uses an iterative and incremental procedure to estimate the plastic strains from the material stress-strain properties and a simulated plasticity hardening model. The simplified method was exercised on a number of problems involving uniaxial and multiaxial loading, isothermal and nonisothermal conditions, and different materials and plasticity models. Good agreement was found between these analytical results and nonlinear finite element solutions for these problems. The simplified analysis program used less than 1 percent of the CPU time required for a nonlinear finite element analysis.
The thermochemical and flammability properties of some thermally stable polymers considered for use in aircraft interiors are described. The properties studied include: (1) thermomechanical properties such as glass transition and melt temperature; (2) dynamic thermogravimetric analysis in anaerobic environment; (3) flammability properties such as oxygen index, flame spread, and smoke evolution; and (4) selected physical properties. The thermoplastic polymers evaluated included polyphenylene sulfide, polyaryl sulfone, 9,9-bis(4-hydroxyphenyl)-fluorene polycarbonate-poly(dimethylsiloxane) and polyether sulfone. The thermoset polymers evaluated included epoxy, bismaleimide, a modified phenolic and polyaromatic melamine resin. These resins were primarily used in the fabrication of glass reinforced prepregs for the construction of experimental panels. Test results and relative rankings of some of the flammability parameters are presented and the relationship of the molecular structure, char yield, and flammability properties of these polymers are discussed.
The thermochemical and flammability properties of some thermally stable polymers considered for use in aircraft interiors are described. The properties studied include: (1) thermomechanical properties such as glass transition and melt temperature; (2) dynamic thermogravimetric analysis in anaerobic environment; (3) flammability properties such as oxygen index, flame spread, and smoke evolution; and (4) selected physical properties. The thermoplastic polymers evaluated include polyphenylene sulfide, polyaryl sulfone, 9,9-bis(4-hydroxyphenyl)-fluorene polycarbonate-poly(dimethylsiloxane) and polyether sulfone. The thermoset polymers evaluated include epoxy, bismaleimide, a modified phenolic, and polyaromatic melamine resin. These resins were primarily used in the fabrication of glass-reinforced prepregs for the construction of experimental panels. Test results and relative rankings of some of the flammability parameters are presented, and the relationship of the molecular structure, char yield, and flammability properties of these polymers are discussed.