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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Al-Li Alloy 1441 for Fuselage Applications

A cooperative investigation was conducted to evaluate Al-Cu-Mg-Li alloy 1441 for long service life fuselage applications. Alloy 1441 is currently being used for fuselage applications on the Russian Be-103 amphibious aircraft, and is expected to be used for fuselage skin on a new Tupolev business class aircraft. Alloy 1441 is cold-rollable and has several attributes that make it attractive for fuselage skin applications. These attributes include lower density and higher specific modulus with similar strength as compared to conventional Al-Cu-Mg alloys. Cold-rolled 1441 Al-Li sheet specimens were tested at NASA Langley Research Center (LaRC) and at the All-Russia Institute of Aviation Materials (VIAM) in Russia to evaluate tensile properties, fracture toughness, impact resistance, fatigue life and fatigue crack growth rate. In addition, fuselage panels were fabricated by Tupolev Design Bureau (TDB) using 1441 skins and Al-Zn-Mg-Cu alloy stiffeners. The panels were subjected to cyclic pressurization fatigue tests at TDB and at LaRC to simulate fuselage pressurization/depressurization during aircraft service. This paper discusses the results from this investigation.

Bird, R. K.↗
NASA NTRSDate not supplied

Proposed Reliability-Based Damage Tolerance Guidelines for Space Systems

Deterministic damage tolerance guidelines for highly reusable and efficiently designed launch systems can be challenging to meet and result in overly conservative assessments for tightly controlled manufacturing processes. Deterministic approaches may be unconservative when the structure is workmanship sensitive and there is a wide spread in fracture properties. Reliability-based damage tolerance assessments targeting a component reliability over the service life commensurate to mission risk posture is a promising alternative. Low production rates, short fleets, and lack of standards or guidance has slowed down widespread adoption of this method. Guidance for the robust application of reliability-based damage tolerance for space systems are proposed. These guidelines cover the treatment of uncertainty in damage tolerance analysis, the collection of data to develop probabilistic distributions, uncertainty propagation methods, and types of hardware.

Reliability-Based Damage Tolerance↗
NASA NTRS2025

Improving Adhesive Bondline Time of Flight Predictions During Autoclave Cure Utilizing Machine Learning

Composite materials are increasingly being used in aerospace applications due to their superior strength-to-weight ratio compared to commonly used metals. A current limitation to widespread adoption is the certification of adhesively bonded joints. One approach to improving adhesive bonding in composites is accurately measuring the thickness of adhesive bondlines in composite laminates. Precise bondline thickness control is essential for aerospace applications where adhesive layer thickness directly affects joint fracture properties and structural performance. This study focused on implementing machine learning techniques to determine the ultrasonic time of flight (directly correlated to thickness) in adhesive bondlines throughout autoclave cure cycles. A high-temperature (use up to 180°C) ultrasonic scanning system was deployed in an autoclave to provide time of flight data through composite panels. Three experiments were conducted on the curing of 305 mm × 305 mm unidirectional composite panels. In the first experiment, a piecewise function was fit for the temperature correction factor to account for changing autoclave temperatures. Due to deficiencies in the first calibration experiment, a second experiment was run, and the results were used to train a machine learning model. The revised experiment, in combination with the machine learning model, significantly increased the accuracy of the bondline time of flight predictions (~14% error reduced to <1%). Data was processed using the Regression Learner Application in MATLAB®, with a Support Vector Machine selected for the model. The result was a machine learning algorithm capable of reliably quantifying ultrasonic time of flight through adhesive bondlines. The third experiment provided independent test data for the machine learning model, demonstrating that the model produces accurate predictions from data beyond its training set.

Machine Learning↗
DOE OSTI2011

DEVELOPMENT OF IN SITU TECHNIQUES FOR TORSION AND TENSION TESTING IN HYDROGEN ENVIRONMENT

Reliability of hydrogen storage tanks is significantly influenced by the mechanical performance of the container materials in the hydrogen environment. Fracture behavior and fracture toughness are of specific interest since they are relevant to many catastrophic failures. However, many conventional fracture testing techniques are difficult to be realized under the presence of hydrogen. Thus it is desired to develop novel in situ techniques to study the fracture behavior of structural materials in hydrogen environments. In this study, special testing apparatus were designed to facilitate in situ fracture testing in H2. In addition to a multi-notch tensile fixture, a torsional fixture was developed to utilize an emerging fracture testing technique, Spiral Notch Torsion Test (SNTT). The design concepts will be discussed. Preliminary in situ testing results indicated that the presence of H2 significantly reduces the fracture toughness of 4340 pipeline steels by up to 50 percent. On the other hand, SNTT tests conducted in air demonstrated a significant fracture toughness reduction in samples subject to Gleeble heat treatment, which illustrated the effect of welding on the fracture toughness of this material.

08 HYDROGEN↗
DOE OSTI2011

Fractographic study of epoxy fractured under mode I loading and mixed mode I/III loading

Fiber reinforced polymeric composite materials are widely used in structural components such as wind turbine blades, which are typically subject to complicated loading conditions. Thus, material response under mixed mode loading is of great significance to the reliability of these structures. Epoxy is a thermosetting polymer that is currently used in manufacturing wind turbine blades. The fracture behavior of epoxy is relevant to the mechanical integrity of the wind turbine composite materials. In this study, a novel fracture testing methodology, the spiral notch torsion test (SNTT), was applied to study the fracture behavior of an epoxy material. SNTT samples were tested using either monotonic loading or cyclic loading, while both mode I and mixed mode I/III loading conditions were used. Fractographic examination indicated the epoxy samples included in this study were prone to mode I failure even when the samples were subject to mixed mode loading. Different fatigue precracks were observed on mode I and mixed mode samples, i.e. precracks appeared as a uniform band under mode I loading, and a semi-ellipse under mixed mode loading. Fracture toughness was also estimated using quantitative fractography.

17 WIND ENERGY↗
DOE OSTI2011

Heat Treatment Effect on Fracture Toughness of F82H Irradiated in HFIR

Irradiation hardening and fracture toughness of reduced-activation ferritic/martensitic steel F82H after irradiation were investigated with a focus on changing the fracture toughness transition temperature as a result of several heat treatments. The specimens were standard F82H-IEA (IEA), F82H-IEA with several heat treatments (Mod1 series) and a heat of F82H (Mod3) containing 0.1 % tantalum. The specimens were irradiated up to 20 dpa at 300oC in the High Flux Isotope Reactor under a collaborative research program between JAEA/US-DOE. The results of hardness tests showed that irradiation hardening of IEA was comparable with that of Mod3. However, the fracture toughness-transition temperature of Mod3 was lower than that of IEA. The transition temperature of Mod1 was also lower than that of the IEA heat. These results suggest that optimization of specifications on the heat treatment condition and modification of the minor alloying elements seem to be effective to reduce the fracture toughness-transition temperature after irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Investigating Fracture Behaviors of Polymer and Polymeric Composite Materials Using Spiral Notch Torsion Test

Wind turbine blades are usually fabricated from fiber reinforced polymeric (FRP) materials, which are subject to complex loading conditions during service. The reliability of the blades thus depends on the mechanical behaviors of the FRP under various loading conditions. Specifically, the fracture behavior of FRP is of great importance to both the scientific research community and the wind industry. In the current project, a new testing technique is proposed based on the spiral notch torsion test (SNTT) to study the fracture behavior of composite structures under mixed mode loading conditions, particularly under combined Mode I (flexural or normal tensile stress) and Mode III (torsional shear stress) loading. For the SNTT test method, round-rod specimens with V-grooved spiral lines are subjected to pure torsion. Depending on the pitch angle of the spiral lines, pure Mode I, pure Mode III, or mixed Mode I/Mode III loading conditions can be simulated. A three dimensional finite element analysis is then used to evaluate the fracture toughness and energy release rate of SNTT specimens. In the current study, both epoxy and fiberglass reinforced epoxy materials are investigated using the SNTT technique. This paper will discuss the fracture behaviors of mode I and mixed mode samples, with or without fatigue precrack. In addition, results from fractographic study and finite element analysis will be presented and discussed in detail.

17 WIND ENERGY↗
DOE OSTI2012

ADDITIONAL STRESS AND FRACTURE MECHANICS ANALYSES OF PRESSURIZED WATER REACTOR PRESSURE VESSEL NOZZLES

In past years, the authors have undertaken various studies of nozzles in both boiling water reactors (BWRs) and pressurized water reactors (PWRs) located in the reactor pressure vessel (RPV) adjacent to the core beltline region. Those studies described stress and fracture mechanics analyses performed to assess various RPV nozzle geometries, which were selected based on their proximity to the core beltline region, i.e., those nozzle configurations that are located close enough to the core region such that they may receive sufficient fluence prior to end-of-life (EOL) to require evaluation of embrittlement as part of the RPV analyses associated with pressure-temperature (P-T) limits. In this paper, additional stress and fracture analyses are summarized that were performed for additional PWR nozzles with the following objectives: To expand the population of PWR nozzle configurations evaluated, which was limited in the previous work to just two nozzles (one inlet and one outlet nozzle). To model and understand differences in stress results obtained for an internal pressure load case using a two-dimensional (2-D) axi-symmetric finite element model (FEM) vs. a three-dimensional (3-D) FEM for these PWR nozzles. In particular, the ovalization (stress concentration) effect of two intersecting cylinders, which is typical of RPV nozzle configurations, was investigated. To investigate the applicability of previously recommended linear elastic fracture mechanics (LEFM) hand solutions for calculating the Mode I stress intensity factor for a postulated nozzle corner crack for pressure loading for these PWR nozzles. These analyses were performed to further expand earlier work completed to support potential revision and refinement of Title 10 to the U.S. Code of Federal Regulations (CFR), Part 50, Appendix G, Fracture Toughness Requirements, and are intended to supplement similar evaluation of nozzles presented at the 2008, 2009, and 2011 Pressure Vessels and Piping (PVP) Conferences. This work is also relevant to the ongoing efforts of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel (B&PV) Code, Section XI, Working Group on Operating Plant Criteria (WGOPC) efforts to incorporate nozzle fracture mechanics solutions into a revision to ASME B&PV Code, Section XI, Nonmandatory Appendix G.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

A FRAMEWORK TO DEVELOP FLAW ACCEPTANCE CRITERIA FOR STRUCTURAL INTEGRITY ASSESSMENT OF MULTIPURPOSE CANISTERS FOR EXTENDED STORAGE OF USED NUCLEAR FUEL

A multipurpose canister (MPC) made of austenitic stainless steel is loaded with used nuclear fuel assemblies and is part of the transfer cask system to move the fuel from the spent fuel pool to prepare for storage, and is part of the storage cask system for on-site dry storage. This weld-sealed canister is also expected to be part of the transportation package following storage. The canister may be subject to service-induced degradation especially if exposed to aggressive environments during possible very long-term storage period if the permanent repository is yet to be identified and readied. Stress corrosion cracking may be initiated on the canister surface in the welds or in the heat affected zone because the construction of MPC does not require heat treatment for stress relief. An acceptance criteria methodology is being developed for flaw disposition should the crack-like defects be detected by periodic Inservice Inspection. The external loading cases include thermal accident scenarios and cask drop conditions with the contribution from the welding residual stresses. The determination of acceptable flaw size is based on the procedure to evaluate flaw stability provided by American Petroleum Institute (API) 579 Fitness-for-Service (Second Edition). The material mechanical and fracture properties for base and weld metals and the stress analysis results are obtained from the open literature such as NUREG-1864. Subcritical crack growth from stress corrosion cracking (SCC), and its impact on inspection intervals and acceptance criteria, is not addressed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Influence of specimen size/type on the fracture toughness of five irradiated RPV materials

The Heavy-Section Steel Irradiation (HSSI) Program had previously irradiated five reactor pressure vessel (RPV) steels/welds at fast neutron fluxes of about 4 to 8 x 10 11 n/cm 2 /s (>1 MeV) to fluences from 0.5 to 3.4 10 19 n/cm 2 and at 288 °C. The unirradiated fracture toughness tests were performed by Oak Ridge National Laboratory with 12.7-mm and 25.4-mm thick (0.5T and 1T) compact specimens, while the HSSI Program provided tensile and 5 x 10-mm three-point bend specimens to SCK-CEN for irradiation in the in-pile section of the Belgian Reactor BR2 at fluxes > 10 13 n/cm 2 /s and subsequent testing by SCK-CEN. The BR2 irradiations were conducted at about 2 and 4 x 10 13 n/cm 2 /s with irradiation temperature between 295 °C and 300 °C (water temperature), and to fluences between 6 and 10 x 10 19 n/cm 2 . The irradiation-induced shifts of the Master Curve reference temperatures, ΔT 0 , for most of the materials deviated from the embrittlement correlations much more than expected, motivating the testing of 5 x 10-mm three-point bend specimens of all five materials in the unirradiated condition to eliminate specimen size and geometry as a variable. Tests of the unirradiated small bend specimens resulted in Master Curve reference temperatures, T 0 , 25 °C to 53 °C lower than those from the larger compact specimens, meaning that the irradiation-induced reference temperature shifts, ΔT 0 , were larger than the initial measurements, resulting in much improved agreement between the measured and predicted fracture toughness shifts.

36 MATERIALS SCIENCE↗
DOE OSTI2015

RECENT PROGRESS IN THE DEVELOPMENT OF DUCTILE-PHASE TOUGHENED TUNGSTEN FOR PLASMA-FACING MATERIALS: W-Ni-Fe COMPOSITES

A promising approach to increasing fracture toughness and decreasing the DBTT of a W-alloy is by ductile-phase toughening (DPT) [1-3]. In this method, a ductile phase is included in a brittle matrix to prevent fracture propagation by crack bridging. W-Ni-Fe alloys consisting of nearly spherical W-particles embedded within a Fe-Ni-W ductile matrix are being manipulated by hot-rolling to create lamellar W/Fe-Ni-W composites with anisotropic fracture properties.

Henager, Charles H.↗
DOE OSTI2016

Subcritical fracturing of shales under chemically reactive conditions

Growth of opening-mode fractures under chemically reactive subsurface conditions is potentially relevant for seal integrity in subsurface CO2 storage and hazardous waste disposal. Using double-torsion load relaxation tests we determine mode-I fracture toughness (KIC), subcritical index (SCI), and the stress-intensity factor vs fracture velocity (K-V) behavior of Marcellus, Woodford, and Mancos shales. Samples are tested under ambient air and aqueous conditions with variable NaCl and KCl concentrations, variable pH, and temperatures of up to 70°C. Under ambient air condition, KIC determined from double torsion tests is 1.3, 0.6, and 1.1 MPa∙m1/2 for Marcellus, Woodford, and Mancos shales, respectively. SCI under ambient air condition is between 55 and 90 for the shales tested. Tests in aqueous solutions show a significant drop of KIC compared to ambient air condition. For tests in deionized water, KIC reduction is 18.5% for Marcellus and 47.0% for Woodford. The presence of aqueous fluids also results in a reduction of the SCI up to 85% compared to ambient condition. K-V curves generally obey a power-law relation throughout the load-relaxation period. However, aqueous-based tests on samples result in K-V curves deviating from the power-law relation, with the SCI values gradually decreasing with time during the relaxation period. This non-power-law behavior is obvious in Woodford and Mancos, but negligible in Marcellus. We find that the shales interact with the aqueous solution both at the fracture tip and within the rock matrix during subcritical fracturing. For Marcellus shale, water mainly interacts with the fracture tip on both tests due to low matrix permeability and less reactive mineral composition. However, Woodford and Mancos react strongly with water causing significant sample degradation. The competition between degradation and fracture growth results in the time-dependent SCI: at lower fracture velocities, the tip interacts longer with the chemically altered area around the tip; at higher fracture velocities, the fracture propagates through the altered area before significant degradation. Our results display strong weakening effects of chemically reactive fluids on subcritical fracture properties with implications on subsurface storage seal performance.

58 GEOSCIENCES↗
DOE OSTI2016

Grizzly: A Multi-scale and Multi-Physics Tool to Model Aging of Nuclear Power Plant Components

Grizzly is a multi-scale multi-physics tool being developed at Idaho National Laboratory (INL) as part of the US Department of Energy's Light Water Reactor Sustainability program to provide improved safety assessments of systems, components, and structures in nuclear power plants subjected to age-related degradation. Its goal is to provide an improved scientific basis for decisions surrounding license renewal, which would permit operation of commercial nuclear power plants beyond 60 years. Grizzly is based on INL's MOOSE framework, which enables multi-physics simulations in a massively parallel computing environment. The reactor pressure vessel (RPV) has been chosen as the initial application for Grizzly. The primary concern for the RPV is that it becomes increasingly susceptible to fracture initiation at the sites of pre-existing flaws over time. This is because exposure to irradiation and high temperatures embrittles the steel. Assessing the safety of an RPV under transient conditions involves simulations at multiple scales. At the engineering scale, strongly coupled equations of heat conduction and solid mechanics are solved to simulate the global response of the RPV to accident conditions. Sub-models are used to represent regions with pre-existing flaws and the stress intensity factors are evaluated from the domain integrals. Crack propagation is then determined using a model that provides the temperature and neutron fluence dependent fracture toughness of the RPV steel. The ability of Grizzly to provide accurate engineering scale estimates of RPV safety beyond 60 years of operation strongly relies on the predictability of the embrittlement model. Multiple models for embrittlement have been proposed, and the physically based empirical model is implemented in Grizzly. However, the formation of late blooming phases greatly reduces the confidence on the extrapolated values obtained from embrittlement model, which is further exacerbated by the absence of real field data for validation. Experimentally validated lower length scale models can significantly improve the predictability of the embrittlement model beyond the calibrated range and the development of such models is another ongoing effort in Grizzly. The modeling activity in Grizzly spans across different length scales, and can be divided into: (i) Irradiation induced microstructure evolution at the atomistic and single crystal length scale using molecular dynamics, atomistic kinetic Monte-Carlo, phase-field and rate theory; (ii) Effect of the irradiation induced defects on the flow stress and fracture processes at the polycrystalline scale using crystal plasticity. Subsequently, the prediction from these models can be used to obtain irradiation induced ductile-to-brittle transition temperature (DBTT) shifts from specimen-scale simulations; (iii) Global thermo-mechanical response of the RPV under normal and accident scenarios, and probabilistic risk analyses at the engineering scale using the DBTT shifts obtained from the lower length scale models. The item (i) has been discussed in a previous report. In this extended abstract an overview of items (ii) and (iii) is provided. The extended abstract summarizes the current status of the modeling effort under Grizzly. At the engineering scale, reduced order model development is underway using the statistical tool RAVEN. This will allow probabilistic analysis considering a wide range of flaw topologies in a computationally efficient manner. Coupling the irradiation induced defect growth predictions to crystal plasticity is also in progress. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1973

The effects of shot-peening residual stresses on the fracture and crack growth properties of D6AC steel

The fracture strength and cyclic crack-growth properties of surface-flawed, shot-peened D6AC steel plate were investigated. For short crack lengths (up to 1.5mm) simple linear elastic fracture mechanics - based only on applied loading - did not predict the fracture strengths. Also, Paris' Law for cyclic crack growth did not correlate the crack-growth behavior. To investigate the effect of shot-peening, additional fracture and crack-growth tests were performed on material which was precompressed to remove the residual stresses left by the shot-peening. Both tests and analysis show that the shot-peening residual stresses influence the fracture and crack-growth properties of the material. The analytical method of compensating for residual stresses and the fracture and cyclic crack-growth test results and predictions are presented.

Elber, W.↗
DOE OSTI2017

A Numerical Study of Factors Affecting Fracture-Fluid Cleanup and Produced Gas/Water in Marcellus Shale: Part II

Horizontal wells combined with successful multi-stage hydraulic fracture treatments are currently the most established method for effectively stimulating and enabling economic development of gas bearing organic-rich shale formations. Fracture cleanup in the Stimulated Reservoir Volume (SRV) is critical to stimulation effectiveness and long-term well performance. However, fluid cleanup is often hampered by formation damage, and post-fracture well performance frequently falls below expectations. A systematic study of the factors that hinder fracture fluid cleanup in shale formations can help optimize fracture treatments and better quantify long term volumes of produced water and gas. Fracture fluid cleanup is a complex process influenced by multi-phase flow through porous media (relative permeability hysteresis, capillary pressure etc.), reservoir rock and fluid properties, fracture fluid properties, proppant placement, fracture treatment parameters, and subsequent flowback and field operations. Changing SRV and fracture conductivity as production progresses further adds to the complexity of this problem. Numerical simulation is the best, and most practical approach to investigate such a complicated blend of mechanisms, parameters, their interactions, and subsequent impact on fracture fluid cleanup and well deliverability. In this paper, a 3-dimensional, 2-phase, dual-porosity model was used to investigate the impact of multiphase flow, proppant crushing, proppant diagenesis, shut-in time, reservoir rock compaction, gas slippage, and gas desorption on fracture fluid cleanup, and well performance in Marcellus shale. The research findings have shed light on the factors that substantially constrains efficient fracture fluid cleanup in gas shales, and provided guidelines for improved fracture treatment designs and water management.

58 GEOSCIENCES↗
DOE OSTI2018

Modelling DC responses of 3D complex fracture networks

Here, the determination of the geometrical properties of fractures plays a critical role in many engineering problems to assess the current hydrological and mechanical states of geological media and to predict their future states. However, numerical modeling of geoelectrical responses in realistic fractured media has been challenging due to the explosive computational cost imposed by the explicit discretizations of fractures at multiple length scales, which often brings about a tradeoff between computational efficiency and geologic realism. Here, we use the hierarchical finite element method to model electrostatic response of realistically complex 3D conductive fracture networks with minimal computational cost.

58 GEOSCIENCES↗