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At least 217 records · Page 12

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗

NASA NTRS2016

Temperature Dependence of Electrical Resistance of Woven Melt-Infiltrated SiCf/SiC Ceramic Matrix Composites

Recent studies have successfully shown the use of electrical resistance (ER)measurements to monitor room temperature damage accumulation in SiC fiber reinforced SiC matrix composites (SiCf/SiC) Ceramic Matrix Composites (CMCs). In order to determine the feasibility of resistance monitoring at elevated temperatures, the present work investigates the temperature dependent electrical response of various MI (Melt Infiltrated)-CVI (Chemical Vapor Infiltrated) SiC/SiC composites containing Hi-Nicalon Type S, Tyranno ZMI and SA reinforcing fibers. Test were conducted using a commercially available isothermal testing apparatus as well as a novel, laser-based heating approach developed to more accurately simulate thermomechanical testing of CMCs. Secondly, a post-test inspection technique is demonstrated to show the effect of high-temperature exposure on electrical properties. Analysis was performed to determine the respective contribution of the fiber and matrix to the overall composite conductivity at elevated temperatures. It was concluded that because the silicon-rich matrix material dominates the electrical response at high temperature, ER monitoring would continue to be a feasible method for monitoring stress dependent matrix cracking of melt-infiltrated SiC/SiC composites under high temperature mechanical testing conditions. Finally, the effect of thermal gradients generated during localized heating of tensile coupons on overall electrical response of the composite is determined.

Ceramic Matrix Composites↗

DOE OSTI2025

Mechanical Characteristics of Additively Manufactured ODS 316L and 316H Alloys with and Without Post-build Processing

This research aims to explore an accelerated development path for oxide dispersion-strengthened (ODS) alloys by integrating additive manufacturing (AM) technologies with recent advances in ODS materials and traditional manufacturing methods. Novel AM and post-build processing routes have been developed for ODS austenitic alloys, specifically Fe-Cr-Ni alloys like 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the effects of process variables on microstructure and properties, aiming for an economically feasible route property optimization. Traditionally, ODS alloy production involves multi-day high-energy mechanical milling of alloy powder with yttria (Y 2 O 3 ) followed by powder consolidation via extrusion or other methods and additional thermomechanical processing (TMP) for property control. Here, to address these challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes focusing on AM and traditional TMP methods. The new ODS alloy processing routes have achieved up to a 400% increase in yield strength and a 60% increase in ultimate tensile strength compared to wrought stainless steels while still maintaining significant ductility and fracture toughness. This paper details the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

Byun, Thak Sang [Oak Ridge National Laboratory (OR↗

NASA NTRS2009

Pin Tool Geometry Effects in Friction Stir Welding

In friction stir welding (FSW) there is significant evidence that material can take one of two different flow paths when being displaced from its original position in front of the pin tool to its final position in the wake of the weld. The geometry of the pin tool, along with the process parameters, plays an important role in dictating the path that the material takes. Each flow path will impart a different thermomechanical history on the material, consequently altering the material microstructure and subsequent weld properties. The intention of this research is to isolate the effect that different pin tool attributes have on the flow paths imparted on the FSWed material. Based on published weld tool geometries, a variety of weld tools were fabricated and used to join AA2219. Results from the tensile properties and microstructural characterization will be presented.

Querin, J. A.↗

NASA NTRS1994

Application of an Energy-Based Life Prediction Model to Bithermal and Thermomechanical Fatigue

The inelastic hysteresis energy applied to the material in a cycle is used as the basis for predicting nonisothermal fatigue life of a wrought cobalt-base superalloy, Haynes 188, from isothermal fatigue data. Damage functions that account for hold-time effects and time-dependent environmental phenomena such as oxidation and hot corrosion are proposed in terms of the inelastic hysteresis energy per cycle. The proposed damage functions are used to predict the bithermal and thermomechanical fatigue lives of Haynes 188 between 316 and 760 C from isothermal fatigue data. Predicted fatigue lives of all but two of the nonisothermal tests are within a factor of 1.5 of the experimentally observed lives.

Radhakrishnan, V. M.↗

NASA NTRS2000

HOTCFGM-2D: A Coupled Higher-Order Theory for Cylindrical Structural Components with Bi-Directionally Components with Bi-Directionally Graded Microstructures

The objective of this two-year project was to develop and deliver to the NASA-Glenn Research Center a two-dimensional higher-order theory, and related computer codes, for the analysis and design of cylindrical functionally graded materials/structural components for use in advanced aircraft engines (e.g., combustor linings, rotor disks, heat shields, brisk blades). To satisfy this objective, two-dimensional version of the higher-order theory, HOTCFGM-2D, and four computer codes based on this theory, for the analysis and design of structural components functionally graded in the radial and circumferential directions were developed in the cylindrical coordinate system r-Theta-z. This version of the higher-order theory is a significant generalization of the one-dimensional theory, HOTCFGM-1D, developed during the FY97 for the analysis and design of cylindrical structural components with radially graded microstructures. The generalized theory is applicable to thin multi-phased composite shells/cylinders subjected to steady-state thermomechanical, transient thermal and inertial loading applied uniformly along the axial direction such that the overall deformation is characterized by a constant average axial strain. The reinforcement phases are uniformly distributed in the axial direction, and arbitrarily distributed in the radial and circumferential direction, thereby allowing functional grading of the internal reinforcement in the r-Theta plane. The four computer codes fgmc3dq.cylindrical.f, fgmp3dq.cylindrical.f, fgmgvips3dq.cylindrical.f, and fgmc3dq.cylindrical.transient.f are research-oriented codes for investigating the effect of functionally graded architectures, as well as the properties of the multi-phase reinforcement, in thin shells subjected to thermomechanical and inertial loading, on the internal temperature, stress and (inelastic) strain fields. The reinforcement distribution in the radial and circumferential directions is specified by the user. The thermal and inelastic properties of the individual phases can vary with temperature. The inelastic phases are presently modeled by the power-law creep model generalized to multi-directional loading (within fgmc3dq.cylindrical.f and fgmc3dq.cylindrical.transient.f for steady-state and transient thermal loading, respectively), and incremental plasticity and GVIPS unified viscoplasticity theories (within the steady-state loading versions fgmp3dq.cylindrical.f and fgmgvips3dq.cylindrical.f).

Pindera, Marek-Jerzy↗

DOE OSTI2024

Finite element procedure for thermomechanical and structural integrity analysis of beam intercepting devices subjected to free electron laser

High-energy particles, including photons (x-ray, γ-ray, bremsstrahlung), electrons, and protons, possess the capability to penetrate materials and deposit energy within them. The degree of absorption depends on both the energy and type of particles, as well as the properties of the materials with which they interact. This energy deposition can manifest either at the material's surface or throughout its volume, potentially resulting in various failure modes. The primary aim of this paper is to establish a structured analysis methodology for evaluating the structural integrity of beam-intercepting devices when subjected to high-energy particles. Here, the paper also reviews some of the underlying physics, pertinent to the scope of the thermomechanical analysis, potential failure modes, and introduces verification and validation methodologies. Engineers and researchers can utilize the guidelines presented in this paper to effectively plan the development of beam intercepting devices, thereby ensuring their reliability and performance in the presence of high-energy particle exposure.

Finite element analysis↗

DOE OSTI2022

A Modeling and Neutron Diffraction Study of the High Temperature Properties of Sub-Stoichiometric Yttrium Hydride for Novel Moderator Applications

Low-enriched-uranium (LEU) reactor systems utilize moderators to improve neutron economy. Solid yttrium hydride is one of the primary moderator candidates for high-temperature (>700 °C) nuclear reactor applications. This is due to its ability to retain hydrogen at elevated temperatures compared to other metal hydrides. For reactor modeling purposes, both neutronic and thermos-mechanical modeling, several high-temperature properties for sub-stoichiometric yttrium hydride (YH2−x) are needed. In this paper, we present an atomistics and a neutron diffraction study of the high-temperature properties of Y and YH2−x. Specifically, we focus on the thermal lattice expansion effects in yttrium metal and yttrium hydride, which also govern bulk thermal expansion. Previously reported physical and mechanical properties for sub-stoichiometric yttrium hydride at ambient conditions are expanded using lattice dynamics to take into account high-temperature effects. Accordingly, an array of newly generated properties is presented that enables high-fidelity neutronics, and thermomechanical modeling. These properties include various elastic moduli, thermal expansion parameters for yttrium and yttrium hydride, and single-phase (YH2−x) and two-phase (Y + YH2−x) density as a function of stoichiometry and density.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Thermomechanical buckling of multilayered composite panels with cutouts

A study is made of the thermomechanical buckling of flat unstiffened composite panels with central circular cutouts. The panels are subjected to combined temperature changes and applied edge loading (or edge displacements). The analysis is based on a first-order shear deformation plate theory. A mixed formulation is used with the fundamental unknowns consisting of the generalized displacements and the stress resultants of the plate. Both the stability boundary and the sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the buckling response to variations in the different lamination and material parameters of the panel. Numerical results are presented showing the effects of the variations in the hole diameter, laminate stacking sequence, fiber orientation, and aspect ratio of the panel on the thermomechanical buckling response and its sensitivity coefficients.

Noor, Ahmed K.↗

NASA NTRS1994

Thermomechanical buckling of multilayered composite panels with cutouts

THERMOMECHANICAL BUCKLING↗

NASA NTRS1994

Thermomechanical buckling of multilayered composite panels with cutouts

Noor, Ahmed K.↗

DOE OSTI2025

Radiation damage effects in beryllium for next generation neutrino beam targetry (Final Technical Report)

Current and future high-power accelerators put severe requirements on materials used for target and beam windows and target facilities have been recognized as a critical challenge in development of future particle accelerators. In accelerators, window and target materials are exposed to extreme conditions, which include bombardment with very high energy protons (1- 100 GeV) and thermomechanical shock waves. Radiation can cause direct damage in the material, and it leads to production of transmutation products (especially helium), both phenomena having a potential adverse effect on the stability and durability of the target/window material. At high enough temperatures, He can aggregate to form gas bubbles, which in turn cause significant dimensional changes (swelling), enable easy crack propagation, and eventually cause failure by fracture. On the other hand, if the temperature is too low, radiation damage accumulates in the form of internal defects (e.g., dislocations), leading to hardening and a decreased ductility of the material. In this project, we will focus on beryllium since it is considered to be one of the candidate materials for beam windows and targets in the next-generation proton accelerators, e.g., the Long Baseline Neutrino Facility (LBNF). Radiation effects in Be have been studied in the context of nuclear fusion reactor applications. However, key differences exist between reactor and accelerator conditions, including neutron vs. proton irradiation, continuous vs. pulsed beam flux, much higher energies of bombarding particles in accelerators, and higher operating temperatures for typical reactors. For example, the impact of beam pulsing on the radiation damage and the He bubble kinetics is largely unknown. While results obtained on Be from fusion research might not be directly transferrable to understanding target materials, there is an opportunity to bring state-of-the-art tools from materials research in nuclear reactors to aid design of target and beam window materials in high-power accelerators. To this end, the overarching goal of this project are to develop an experimentally-validated computational framework capable of predicting radiation damage evolution in beryllium relevant to beam window and target conditions, focusing on He bubble formation and growth as a function of irradiation temperature. Our model will be based on the cluster dynamics formalism, where size distribution of defects and He bubbles is simulated as a function of time, temperature, and radiation dose. Parameters for the model will be taken from published experiments and from high-fidelity atomistic simulations proposed in this project. In addition, we will carry out a series of targeted ex-situ and in-situ dual-beam experiments using low-energy protons to provide critical data for validation of the model on the effects of radiation on He clustering, He bubble distribution, and dislocation loop density/size in proton irradiated Be.

36 MATERIALS SCIENCE↗

NASA NTRS1987

The effect of bromination of carbon fibers on the coefficient of thermal expansion of graphite fiber-epoxy composites

To examine the effect of bromination of carbon fibers on the coefficient of thermal expansion (CTE) of carbon fiber epoxy composites, several pristine and brominated carbon fiber-epoxy composite samples were subjected to thermomechanical analysis. The CTE's of these samples were measured in the uniaxial and transverse directions. The CTE was dominated by the fibers in the uniaxial direction, while it was dominated by the matrix in the transverse directions. Bromination had no effect on the CTE of any of the composites. In addition, the CTE of fiber tow was measured in the absence of a polymer matrix, using an extension probe. The results from this technique were inconclusive.

Jaworske, D. A.↗

NASA NTRS1995

Thermomechanical postbuckling of multilayered composite panels with cutouts

The results of a study of the detailed thermomechanical postbuckling response characteristics of flat unstiffened composite panels with central circular cutouts are presented. The panels are subjected to combined temperature changes and applied edge loading (or edge displacements). The analysis is based on a first-order shear deformation plate theory. A mixed formulation is used with the fundamental unknowns consisting of the generalized displacements and the stress resultants of the plate. The postbuckling displacements, transverse shear stresses, transverse shear strain energy density, and their sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the post-buckling response to variations in the different lamination and material parameters of the panel. Numerical results are presented showing the effects of the variations in the hole diameter, laminate stacking sequence, fiber orientation, and aspect ratio of the panel on the thermomechanical postbuckling response and its sensitivity to changes in panel parameters.

Noor, Ahmed K.↗

NASA NTRS1992

Thermomechanical buckling and postbuckling of multilayered composite panels

A study is made of the thermomechanical buckling and postbuckling responses of flat unstiffened composite panels. The panels are subjected to combined temperature change and applied edge displacement. The analysis is based on a first-order shear deformation, von Karman type nonlinear plate theory. A mixed formulation is used with the fundamental unknowns consisting of the generalized displacements and the stress resultants of the plate. An efficient multiple-parameter reduction method is used in conjunction with mixed finite element models, for determining the stability boundary and postbuckling response. The reduction method is also used for evaluating the sensitivity coefficients which measure the sensitivity of the buckling and postbuckling responses to variations in the different lamination and material parameters of the panel. Numerical results are presented showing the effects of variations in the laminate stacking sequence, fiber orientation, number of layers and aspect ratio of the panels on their thermomechanical buckling and postbuckling responses and their sensitivity coefficients.

Noor, Ahmed K.↗

NASA NTRS1992

Structural analysis and sizing of stiffened, metal matrix composite panels for hypersonic vehicles

The present method for strength and stability analyses of stiffened, fiber-reinforced composite panels to be used in hypersonic vehicle structures is of great generality, and can be linked with planar finite-element analysis (FEA). Nonlinear temperature and load-dependent material data for each laminate are used to 'build-up' the stiffened panel's membrane, bending, and membrane-bending coupling stiffness terms, as well as thermal coefficients. The resulting, FEA-solved thermomechanical forces and moments are used to calculate strain at any location in the panel; this allows an effective ply-by-ply orthotropic strength analysis to be conducted, together with orthotropic instability checks for each laminated segment of the cross-section.

Collier, Craig S.↗

NASA NTRS1988

Life prediction modeling based on strainrange partitioning

Strainrange partitioning (SRP) is an integrated low-cycle-fatigue life predicting system. It was created specifically for calculating cyclic crack initiation life under severe high-temperature fatigue conditions. The key feature of the SRP system is its recognition of the interacting mechanisms of cyclic inelastic deformation that govern cyclic life at high temperatures. The SRP system bridges the gap between the mechanistic level of understanding that breeds new and better materials and the phenomenological level wherein workable engineering life prediction methods are in great demand. The system was recently expanded to address engineering fatigue problems in the low-strain, long-life, nominally elastic regime. This breakthrough, along with other advances in material behavior and testing technology, has permitted the system to also encompass low-strain thermomechanical loading conditions. Other important refinements of the originally proposed method include procedures for dealing with life-reducing effects of multiaxial loading, ratcheting, mean stresses, nonrepetitive (cumulative loading) loading, and environmental and long-time exposure. Procedure were also developed for partitioning creep and plastic strain and for estimating strainrange versus life relations from tensile and creep rupture properties. Each of the important engineering features of the SRP system are discussed and examples shown of how they help toward predicting high-temperature fatigue life under practical, although complex, loading conditions.

Halford, Gary R.↗

DOE OSTI2023

Unexpected Thermomechanical Behavior of Off-Stoichiometry Epoxy/Amine Materials

Recent studies on off-stoichiometric thermosets reveal unique viscoelastic behavior derived from increased free volume and physical interactions between chain ends. To understand structural characteristics arising from cure and its effect on properties, we developed a Monte Carlo model based on step-growth polymerization. Our model accurately predicted structure–property trends for a two-component system of EPON 828 (EPON) and ethylenediamine. A second epoxy monomer, D.E.R. 732 (DER), was investigated to modulate T g . Binary mixtures of EPON and DER in off-stoichiometric, amine-rich formulations resulted in nonlinear evolution of thermomechanical properties with respect to initial formulation stoichiometry. Modifying our model with kinetic parameters allowing for differential epoxide/amine reaction kinetics only partially accounted for trends in T g , suggesting that spatiotemporal contributions-not captured by our model-were significant determinants of material properties compared to polymer architecture for three-component systems. Here these findings underpin the importance of spatial awareness in modeling to inform the development of dynamic thermosets.

36 MATERIALS SCIENCE↗