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DOE OSTI2022

A new woven composite constitutive model validated by shock wave experiments

In this paper, we present results of plate impact simulations of shock compressed woven glass fiber-reinforced plastic (GRP) performed using the Arbitrary Lagrangian–Eulerian three-dimensional finite element code. A hyperelastic large-strain-based empirical Continuum Damage Mechanics (CDM) formulation is employed to describe damage initiation and growth in the shock-compressed GRP. The model parameters calibration scheme utilizes the Velocity Interferometer System for Any Reflector normal particle velocity measurements at the free surface of the GRP target plates. The impact velocity in the experiments ranged from 8.5 to 418 m/s. The finite element model considered planar 0°/90° bidirectional plies with an individual ply thickness of 0.68 mm, stacked to reach a total laminate thickness of 6.8 mm. The anisotropic elastic strains were estimated from the experimentally determined tetragonal symmetry stiffness matrix for the GRP. The strain-based damage model captures several salient features observed in the measured free surface particle wave profiles, including the shock rise time, onset of Elastic—Elastic Cracking, and the shape of the nonlinear portion of the experimental particle velocity profiles. Furthermore, the CDM model predicts the dominant damage mode to be matrix microcracking due to shear and the associated bulk expansion (bulking) under the global compressive loading in the plate impact configuration.

42 ENGINEERING↗

DOE OSTI2024

Emergent tetragonality in a fundamentally orthorhombic material

Symmetry plays a key role in determining the physical properties of materials. By Neumann’s principle, the properties of a material remain invariant under the symmetry operations of the space group to which the material belongs. Continuous phase transitions are associated with a spontaneous reduction in symmetry. Less common are examples where proximity to a continuous phase transition leads to an increase in symmetry. We find signatures of an emergent tetragonal symmetry close to a charge density wave (CDW) bicritical point in a fundamentally orthorhombic material, ErTe 3 , for which the two distinct CDW phase transitions are tuned via anisotropic strain. We first establish that tension along the a axis favors an abrupt rotation of the CDW wave vector from the c to a axis and infer the presence of a bicritical point where the two continuous phase transitions meet. We then observe a divergence of the nematic elastoresistivity approaching this putative bicritical point, indicating an emergent tetragonality in the critical behavior.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Aerosol-Jet Printed Sensors for Environmental, Safety, and Health Monitoring: A Review

An emergent direct-write approach, aerosol-jet printing (AJP), is gaining attention for the deployment of rapid and affordable microadditively manufactured energy-efficient sensors and printed electronics. AJP enables a broad range of ink viscosities (0.001–1 Pa s) for printing diverse materials ranging from ceramics and metals to polymers and biological matter. Reproducible, high-spatial-resolution features (≈10 µm), and wide standoff distances (1–11 mm) between the nozzle and the substrate facilitate conformal printing of complex geometrical designs on nonplanar—e.g., stepped or curved—surfaces. Here this paper aims to provide a comprehensive overview of state-of-the-art AJP-based sensors (e.g., strain and temperature gauges, biosensors, photosensors, humidity and surface acoustic wave sensors, dielectric elastomer actuators, and motion, smoke, and hazardous gas detectors) and to discuss prospective applications. The drive toward cost-effective devices that are smaller, lighter, and better-performing remains a frontier challenge in the field of printed electronics. Consequently, as AJP becomes increasingly utilized in the high-volume manufacturing of miniaturized active and passive sensors, it opens a pathway for facile large-scale fabrication of devices for a wide range of consumer and industrial applications, including transportation, agriculture, infrastructure, aerospace, national defense, and healthcare.

3-dimensional↗

DOE OSTI2026

Atomic Evolution of Hydrogen Intercalation Wave Dynamics in Palladium Nanocrystals Revealed by Liquid-Phase Transmission Electron Microscopy

Solute-intercalation-induced phase separation creates spatial heterogeneities in host materials, a phenomenon ubiquitous in batteries, hydrogen storage, and other energy devices. Despite many efforts, probing intercalation processes at the atomic scale has been a significant challenge. By utilizing liquid-phase transmission electron microscopy (TEM), we study hydrogen (de)intercalation in palladium nanocrystals as a model system and have achieved unprecedented atomic-resolution imaging of hydrogen intercalation wave dynamics. Our observations reveal that intercalation wave mechanisms, instead of shrinking-core mechanisms, prevail at ambient temperature for palladium nanocubes ranging from ∼60 nm down to ∼10 nm. Systematic image analysis uncovers the atomic evolution of the hydrogen intercalation wave, transitioning from nonplanar and inclined boundaries to those closely aligned with {100} planes. Our kinetic Monte Carlo simulations demonstrate that the observed intercalation wave dynamics correspond to sorption pathways minimizing the lattice mismatch strain at the phase boundary. In conclusion, unveiling the atomic intercalation pathways holds profound implications for engineering intercalation-mediated devices and advancements in energy sciences.

Lee, Daewon [Lawrence Berkeley National Laboratory↗

DOE OSTI2022

Development of self-sensing materials for extreme environments based on metamaterial concept and additive manufacturing

Structural health monitoring of an engineered component in a harsh environment is critical for multiple DOE missions including nuclear fuel cycle, subsurface energy production/storage, and energy conversion. Supported by a seeding Laboratory Directed Research & Development (LDRD) project, we have explored a new concept for structural health monitoring by introducing a self-sensing capability into structural components. The concept is based on two recent technological advances: metamaterials and additive manufacturing. A self-sensing capability can be engineered by embedding a metastructure, for example, a sheet of electromagnetic resonators, either metallic or dielectric, into a material component. This embedment can now be realized using 3-D printing. The precise geometry of the embedded metastructure determines how the material interacts with an incident electromagnetic wave. Any change in the structure of the material (e.g., straining, degradation, etc.) would inevitably perturbate the embedded metastructures or metasurface array and therefore alter the electromagnetic response of the material, thus resulting in a frequency shift of a reflection spectrum that can be detected passively and remotely. This new sensing approach eliminates complicated environmental shielding, in-situ power supply, and wire routing that are generally required by the existing active-circuit-based sensors. The work documented in this report has preliminarily demonstrated the feasibility of the proposed concept. The work has established the needed simulation tools and experimental capabilities for future studies.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Stress wave calculations in composite plates using the fast Fourier transform.

The protection of composite turbine fan blades against impact forces has prompted the study of dynamic stresses in composites due to transient loads. The mathematical model treats the laminated plate as an equivalent anisotropic material. The use of Mindlin's approximate theory of crystal plates results in five two-dimensional stress waves. Three of the waves are flexural and two involve in-plane extensional strains. The initial value problem due to a transient distributed transverse force on the plate is solved using Laplace and Fourier transforms. A fast computer program for inverting the two-dimensional Fourier transform is used. Stress contours for various stresses and times after application of load are obtained for a graphite fiber-epoxy matrix composite plate. Results indicate that the points of maximum stress travel along the fiber directions.

Moon, F. C.↗

DOE OSTI2022

Ab initio calculations of third-order elastic coefficients

Third-order elasticity (TOE) theory predicts strain-induced changes in second-order elastic coefficients (SOECs) and can model elastic wave propagation in stressed media. Although third-order elastic tensors have been determined based on first principles in previous studies, their current definition is based on an expansion of thermodynamic energy in terms of the Lagrangian strain near the natural, or zero pressure, reference state. This definition is inconvenient for predictions of SOECs under significant initial stresses. Therefore, when TOE theory is necessary to study the strain dependence of elasticity, the seismological community has resorted to an empirical version of the theory. This study reviews the thermodynamic definition of the third-order elastic tensor and proposes using an “effective” third-order elastic tensor. An explicit expression for the effective third-order elastic tensor is given and verified. Additionally, we extend the ab initio approach to calculate third-order elastic tensors under finite pressure and apply it to two cubic systems, namely, NaCl and MgO. As applications and validations, we evaluate (a) strain-induced changes in SOECs and (b) pressure derivatives of SOECs based on ab initio calculations. Good agreement between third-order elasticity-based predictions and numerically calculated values confirms the validity of our theory.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1981

DC calibration of the strain sensitivity of a single mode optical fiber interferometer

The strain sensitivity of an optical fiber interferometer developed for the detection of pulsed ultrasonic waves in solids was calibrated. Light from the output ends of both fibers was superimposed to form an interference fringe pattern that was interrogated in the far field to give a signal proportional to the differential optical fiber path length. Strain sensitivity is determined by comparing data obtained by clamping and bending the bar at different lengths to simple cantilever beam theory. A minimum theoretical detectable strain of less than 10 to the minus 10th power is indicated.

Claus, R. O.↗

DOE OSTI2022

A continuum damage approach to spallation and the role of microinertia

Spall failure is of interest due to its prevalence in high strain rate problems in which the spallation is driven by the interaction of release waves. In this article, a porosity-based damage model that includes microinertial effects is used to examine spall failure. The model is successfully calibrated to plate impact-driven experiments and then used to evaluate experimental conditions producing more extreme strain rate conditions, such as those in laser-driven experiments. The incorporation of microinertia allows us to better understand the increase in apparent macroscopic spall strength seen at high strain rates. Correspondingly, we conclude that the incorporation of microinertial effects improves the model’s predictive capabilities. Microinertial effects result in more severe local tensile stresses that affect the damage evolution, and microinertia can play a significant role in the approach to the material’s ideal strength at extreme loading rates. Additionally, a preliminary parametric study is also carried out to investigate the role of microstructural aspects such as nucleation volume fraction and initial pore radius. One counter-intuitive result from the microinertial effects is that, for a given nucleation site volume fraction, having larger initial pore nucleation sites can lead to an improved macroscopic spall strength.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Tuning superconductivity and spin-vortex instabilities in CaKFe 4 As 4 through in-plane antisymmetric strains

Lattice strains of appropriate symmetry have served as an excellent tool to explore the interaction of superconductivity in the iron-based superconductors with orthorhombic-nematic and stripe spin-density-wave (SSDW) order. In this Letter, we contribute to a broader understanding of the coupling of strain to superconductivity and competing normal-state orders by studying CaKFe 4 As 4 under large, in-plane strains of B 1 g and B 2 g symmetry. In contrast to the majority of iron-based superconductors, pure CaKFe 4 As 4 exhibits superconductivity with a relatively high transition temperature of T c ∼ 35 K in proximity of a noncollinear, tetragonal, hedgehog spin-vortex crystal (SVC) order. Through experiments and calculations, we demonstrate an anisotropic in-plane strain response of T c and the favored SVC configuration in CaKFe 4 As 4 . This supports a scenario, in which the change in spin fluctuations dominates the strain response of superconducting T c . Overall, by suggesting moderate B 2 g strains as an effective parameter to change the stability of SVC and SSDW, we outline a pathway to a unified phase diagram of iron-based superconductivity. Published by the American Physical Society 2024

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Monolithic AlScN/SiC phononic waveguides for scalable acoustoelectric and quantum devices

Unlike conventional surface acoustic wave devices, phononic waveguide systems enable higher circuit density and stronger strain and piezoelectric fields, making them promising for advanced acoustoelectric and quantum applications. One such material system for generating and guiding phonons at gigahertz frequencies is AlScN on SiC, which can be synthesized by sputter depositing AlScN directly onto SiC wafers. The AlScN on the SiC platform allows for tightly vertically-confined acoustic modes with high electromechanical coupling, high speed of sound, and simple fabrication of strip and rib waveguides. Until now, this system has only been studied as a slab waveguide platform, i.e., without any lateral waveguiding. Here, we demonstrate a two-dimensionally confined phononic architecture in AlScN on SiC that supports guided modes at 2.95 and 4.05 GHz. These modes exhibit strong electromechanical coupling coefficients (k 2 = 4.27%) and propagation losses on the order of 10 dB/mm. Furthermore, this architecture is well-suited for phononic routing and power-efficient active or nonlinear devices such as amplifiers, mixers, and oscillators, and is compatible with the integration of quantum systems, including vacancy centers, charge carriers, photons, and spins, either embedded in SiC or heterogeneously integrated on the surface.

Electrical components↗

NASA NTRS1994

(abstract) Spacecraft Doppler Tracking with the Deep Space Network in the Search for Gravitational Waves

The Deep Space Network generates accurate radio science data observables for investigators who use radio links between spacecraft and the Earth to examine small changes in the phase and/or amplitude of the signal to study a wide variety of structures and phenomena in space. Several such studies are directed at aspects of the theory of general relativity such as gravitational redshift and gravitational waves. A gravitational wave is a propagating, polarized gravitational field, a ripple in the curvature of space-time. In Einstein's theory of general relativity, the waves are propagating solutions of the Einstein field equations. Their amplitudes are dimensionless strain amplitudes that change the fractional difference in distance between test masses and the rates at which separated clocks keep time. Predicted by all relativistic theories of gravity, they are extremely weak (the ratio of gravitational forces to electrical forces is about 10(sup -40)) and are generated at detectable levels only by astrophysical sources - very massive sources under violent dynamical conditions. The waves have never been detected but searches in the low-frequency band using Doppler tracking of many spacecraft have been conducted and others are being planned. Upper limits have been placed on the gravitational wave strength with the best sensitivities to date are for periodic waves being 7 x 10(sup -15).

gravitational waves theory of general relativity D↗

DOE OSTI2022

Effect of Topology on Transient Dynamic and Shock Response of Polymeric Lattice Structures

Architected cellular materials, such as lattice structures, offer potential for tunable mechanical properties for dynamic applications of energy absorption and impact mitigation. In this work, the static and dynamic behavior of polymeric lattice structures was investigated through experiments on octet-truss, Kelvin, and cubic topologies with relative densities around 8%. Here, dynamic testing was conducted via direct impact experiments (25–70 m/s) with high-speed imaging coupled with digital image correlation and a polycarbonate Hopkinson pressure bar. Mechanical properties such as elastic wave speed, deformation modes, failure properties, particle velocities, and stress histories were extracted from experimental results. At low impact velocities, a transient dynamic response was observed which was composed of a compaction front initiating at the impact surface and additional deformation bands whose characteristics matched low strain-rate behavior. For higher impact velocities, shock analysis was carried out using compaction wave velocity and Eulerian Rankine–Hugoniot jump conditions with parameters determined from full-field measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Magnetic properties of metastable honeycomb KCoAsO 4

We present comprehensive neutron scattering data on polycrystalline samples of a new metastable honeycomb material KCoAsO 4 . Below 𝑇 𝑁 = 14 K, the system orders into a zigzag antiferromagnetic state, with spins ordered into alternating ferromagnetic chains similar to the isostructural sister compound KNiAsO 4 . In the case of KCoAsO 4 , we find the moments are robustly canted out of plane closer to the crystallographic 𝑐 axis. A combination of weak interlayer coupling, lattice strain, and inhomogeneities lead to the coexistence of two magnetic ordering wave vectors 𝑘 1 = (1.5 0 0) and 𝑘 2 = (0.5 0 0.5), where the two structures differ only in their layer stacking. Inelastic data show the presence of a spin orbital mode at 24 meV, supporting a pseudospin $\tilde{𝑆}$ = 1/2 Kramer's doublet ground state of the Co 2+ ions. We model the low energy excitations using both a conventional XXZ Hamiltonian and generalized Kitaev Heisenberg Hamiltonian within a linear spin wave limit. While either model can qualitatively reproduce the observed spectra, the lack of fine features and observation of disorder prevent a clear-cut determination of the low energy Hamiltonian. In the case of an XXZ-type model, a large easy-axis anisotropy is necessary to reproduce the gapped spectra and canting of the magnetic moments. For the generalized Kitaev model, despite the large canting of the moments away from the honeycomb layers, we find a noticeable if nondominant Kitaev term persists. In conclusion, the contrast of the magnetic properties of KCoAsO 4 to other cobalt honeycombs highlights the sensitivity of the low energy magnetic properties of Co 2+ to fine details of its crystalline environment.

Honeycomb lattice↗

NASA NTRS1985

Fundamentals of microcrack nucleation mechanics

A foundation for ultrasonic evaluation of microcrack nucleation mechanics is identified in order to establish a basis for correlations between plane strain fracture toughness and ultrasonic factors through the interaction of elastic waves with material microstructures. Since microcracking is the origin of (brittle) fracture, it is appropriate to consider the role of stress waves in the dynamics of microcracking. Therefore, the following topics are discussed: (1) microstress distributions with typical microstructural defects located in the stress field; (2) elastic wave scattering from various idealized defects; and (3) dynamic effective-properties of media with randomly distributed inhomogeneities.

Fu, L. S.↗

NASA NTRS2012

Quasi-Monolithic Structures for Spaceflight Using Hydroxide-Catalysis Bonding

Future space-based missions will take measurements of the universe with unprecedented results. To do this, these missions will require materials and bonding techniques with ever-increasing stability in order to make their measurements. As an example, the Laser Interferometer Space Antenna (LISA) will detect and observe gravitational waves in the 0.1 mHz to 1 Hz frequency range with strain sensitivities on the order of 10(exp -21) at its most sensitive frequency. To make these measurements, critical components such as the optical bench or telescope support structure, will need to have path-length stabilities of better than 1 pm/(square root)Hz. The baseline construction method for the LISA optical bench is to affix fused silica optical components to a Zerodur baseplate using hydroxide-catalysis bonding (HCB). HCB is a recently developed technique that allows the bonding of glasses, some metals, and silicon carbide with significant strength and stability with a bond thickness of less than a few micrometers. In addition, a wide range of surface profiles can be bonded using only a small amount of hydroxide solution. These characteristics make HCB ideal for adhering optical components in complex optical systems. In addition to being used to construct the LISA optical bench, the HCB technique shows great promise for constructing other structures such as hollow retroreflectors to be used for lunar laser ranging, or a visible nulling coronograph to be used for exo-planet detection. Here we present construction techniques that could be used to make an optical bench, hollow retroreflector, nulling coronograph, or other quasi-monolithic structures using HCB. In addition, we present dimensional stability results of an optical bench that was made using HCB, as well as HCB strength measurements.

Preston, Alix↗

DOE OSTI2022

Miniature Beryllium Split-Hopkinson Pressure Bars for Extending the Range of Achievable Strain-Rates

Conventional Split Hopkinson Pressure Bars (SHPB) or “Kolsky” bars are often used for determining the high-rate compressive yield and failure strength of materials. However, for experiments generating very high strain-rates (>10 3 /s) miniaturization of the setup is often required for minimizing the effects of elastic wave dispersion in order to enable the inference of decreasingly short loading events from the data. Miniature aluminum and steel bars are often sufficient for meeting these requirements. However, for high enough strain-rates, miniaturization of steel or aluminum Kolsky bars may require prohibitively small diameter bars and test specimens that could become inappropriate for inferring representative properties of materials with large grain size relative to the test specimen size. The use of a beryllium Kolsky bar setup is expected to enable high rates to be accessible with larger diameter bars/specimen combinations due to the inherent physical properties of beryllium, which are expected to minimize the effects of elastic wave dispersion. For this reason, a series of beryllium Kolsky bars have been developed, and, in this paper, the dispersion characteristics of these bars are measured and compare the data with those of similarly sized 7075-T6 aluminum and C350 maraging steel. The results, which agree well with the theory, show no appreciable frequency dependence of the elastic wavespeed in the data from the beryllium bars, demonstrating its advantage over aluminum and steel in application to Kolsky bars.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps – Phase 2

As the wind turbine industry continues to develop, the technology surrounding the design, development, and manufacturing of blades requires advancement as well. Wind turbine blades continue to increase in size, increasing the cost and time associated with manufacturing. Simulation driven manufacturing cycle design is required for the industry to maintain manufacturing schedules and optimize the manufacturing process. A recent effort to reduce the cycle time of wind blade spar caps encountered a recurring manufacturing defect during the exotherm and curing of the resin system after filling in the vacuum-assisted resin transfer molding (VARTM) process. Thermal waves developed in sections of the spar cap resulting in unacceptable part tolerances, requiring the parts to be thrown out. The first phase of this IACMI project focused on characterizing the fabric and epoxy system used in manufacturing and simulating the manufacturing process to determine the root cause of the thermal waves. The second phase of this project refined and validated the manufacturing simulations. The simulation workflow was then used to analyze multiple cure cycle options to determine if the thermal waves would appear. The estimated filling time from the filling simulation was shown to match well to experiment, and the temperature history from the curing simulation lined up well with experiment. This indicates that these simulations could be used to evaluate future curing cycles to be used with manufacturing. It is recommended that the distortion simulation work be completed for this project, as it would allow for further manufacturing cycle evaluation through the prediction of stresses and strains in the part. This could provide indicators of defects like the thermal waves seen in manufacturing earlier.

17 WIND ENERGY↗