Accelerated Testing of the Mechanical and Thermal Integrity of Polymeric Materials
Long time mechanical and thermal stability of polymeric materials predicted from accelerated testing at increased temperature-time relations
THERMAL INSTABILITY↗
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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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Apollo 14 and 16 Active Seismic Experiments, and Apollo 17 Lunar Seismic Profiling
Seismic refraction experiments were conducted on the moon by Apollo astronauts during missions 14, 16, and 17. Seismic velocities of 104, 108, 92, 114 and 100 m/sec were inferred for the lunar regolith at the Apollo 12, 14, 15, 16, and 17 landing sites, respectively. These data indicate that fragmentation and comminution caused by meteoroid impacts has produced a layer of remarkably uniform seismic properties moonwide. Brecciation and high porosity are the probable causes of the very low velocities observed in the lunar regolith. Apollo 17 seismic data revealed that the seismic velocity increases very rapidly with depth to 4.7 km/sec at a depth of 1.4 km. Such a large velocity change is suggestive of compositional and textural changes and is compatible with a model of fractured basaltic flows overlying anorthositic breccias. 'Thermal' moonquakes were also detected at the Apollo 17 site, becoming increasingly frequent after sunrise and reaching a maximum at sunset. The source of these quakes could possibly be landsliding.
Source record↗
Program definition and preliminary results of a long-term evaluation program of advanced composites for supersonic cruise aircraft applications
Advanced composites will play a key role in the development of the technology required for the design and fabrication of future supersonic vehicles. A program is in progress to determine the time-temperature-stress capabilities of several high-temperature composite materials. Tests included in this study are thermal aging, ambient aging, fatigue, creep, fracture, tensile, and real-time flight-simulation exposure. The program has two parts. The first includes all the material-property determinations and aging and simulation exposures up through 10,000 h. The second continues these tests up to 50,000 cumulative h. The program is currently in the midst of the 10,000-h phase. Some of the results obtained to date and the status of the various tests are discussed.
Kerr, J. R.↗
Structure in the upper lunar crust
Warren and Trice (1975) have shown that bulk elastic properties of lunar samples can be systematically correlated with petrographic classification and descriptions of lithification and disaggregation. The present paper reviews the underlying systematics and uses them to estimate the average degree of lithification and structure densities compatible with the observed seismic profiles in the top 30 km of the moon. The estimates are discussed in terms of some of their implications for the thermal gradient and for annealing and fracture histories. The published lunar seismic profiles are consistent with a sharp gradient in structure density at a depth of about 1 km, from highly fractured lithic units above 1 km to only moderately fractured competent rock below.
Warren, N.↗
Time-temperature-stress capabilities of composite materials for advanced supersonic technology application, phase 1
Implementation of metal and resin matrix composites into supersonic vehicle usage is contingent upon accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive service data, laboratory replication of the flight service will provide the most rapid method of documenting the airworthiness of advanced composite systems. A program in progress to determine the time temperature stress capabilities of several high temperature composite materials includes thermal aging, environmental aging, fatigue, creep, fracture, and tensile tests as well as real time flight simulation exposure. The program has two parts. The first includes all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continues these tests up to 50,000 cumulative hours. Results are presented of the 10,000 hour phase, which has now been completed.
Kerr, J. R.↗
Time-temperature-stress capabilities of composite materials for advanced supersonic technology application
Advanced composites will play a key role in the development of the technology for the design and fabrication of future supersonic vehicles. However, incorporating the material into vehicle usage is contingent on accelerating the demonstration of service capacity and design technology. Because of the added material complexity and lack of extensive data, laboratory replication of the flight service will provide the most rapid method to document the airworthiness of advanced composite systems. Consequently, a laboratory program was conducted to determine the time-temperature-stress capabilities of several high temperature composites. Tests included were thermal aging, environmental aging, fatigue, creep, fracture, tensile, and real-time flight simulation exposure. The program had two phases. The first included all the material property determinations and aging and simulation exposures up through 10,000 hours. The second continued these tests up to 50,000 cumulative hours. This report presents the results of the Phase 1 baseline and 10,000-hr aging and flight simulation studies, the Phase 2 50,000-hr aging studies, and the Phase 2 flight simulation tests, some of which extended to almost 40,000 hours.
Kerr, James R.↗
Monolith catalysts for closed-cycle carbon dioxide lasers
The objective was to explore ways of making a monolithic form of catalyst for CO2 lasers. The approach chosen was to pelletize the catalyst material, Au/MnO2 powder, and epoxy the pellets to stainless steel sheets as structural supports. The CO oxidation reaction over Au/MnO2 powder was found to be first overall, and the reaction rate constant at room temperature was 4.4 +/- 0.3 cc/(g x sec). The activation energy was 5.7 kcal/mol. The BET surface area of the pellets was found to vary from 125 to 140 sq m/g between different batches of catalyst. Pellets epoxied to stainless steel strips showed no sign of fracture or dusting when subjected to thermal tests. Pellets can be dropped onto hard surfaces with chipping of edges but no breakage of the pellets. Mechanical strength tests performed on the pellets showed that the crush strength is roughly one-fourth of the pelletizing force. The apparent activity and activation energy over the pellets were found to be less than over the powdered form of the catalyst. The lower apparent activity and activation energy of the pellets are due to the fact that the internal surface area of a pellet is not exposed to the reactant concentration present in the flowing gas as a result of intrapellet diffusion resistance. Effectiveness factors varied from 0.44, for pellets having thickness of 2 mm and attached with epoxy to a stainless steel strip. The epoxy and the stainless steel strip were found to simply block off one of the circular faces of the pellets. The epoxy did not penetrate the pellets and block the active sites. The values of the effective diffusivities were estimated to be between 2.3 x 10(exp -3) and 4.9 x 10(exp -3) sq cm/s. With measurements performed on one powder sample and one pellet configuration, reasonable accurate predictions can be made of conversions that would be obtained with other pellet thickness and configurations.
Herz, Richard K.↗
Evaluation of Ultra-High Temperature Ceramics for Propulsion Application
Ultra-high temperature ceramic (UHTC) materials consisting of zirconium diboride or hafnium diboride plus silicon carbide offer a combination of properties that make them candidates for airframe leading edges on sharp-bodied reentry vehicles. These UHTC perform well in the environment for such applications, i.e. low pressure air. The purpose of this study was to examine three of these materials under conditions more representative of a propulsion environment, i.e. higher oxygen and total pressure. Results of stren$h and fracture toughness measurements, furnace oxidation, and thermal shock exposures are presented. The poor oxidation resistance of UHTCs is the predominant factor limiting their applicability to propulsion.
Levine, Stanley R.↗
Failure Analysis of Sapphire Refractive Secondary Concentrators
Failure analysis was performed on two sapphire, refractive secondary concentrators (RSC) that failed during elevated temperature testing. Both concentrators failed from machining/handling damage on the lens face. The first concentrator, which failed during testing to 1300 C, exhibited a large r-plane twin extending from the lens through much of the cone. The second concentrator, which was an attempt to reduce temperature gradients and failed during testing to 649 C, exhibited a few small twins on the lens face. The twins were not located at the origin, but represent another mode of failure that needs to be considered in the design of sapphire components. In order to estimate the fracture stress from fractographic evidence, branching constants were measured on sapphire strength specimens. The fractographic analysis indicated radial tensile stresses of 44 to 65 MPa on the lens faces near the origins. Finite element analysis indicated similar stresses for the first RSC, but lower stresses for the second RSC. Better machining and handling might have prevented the fractures, however, temperature gradients and resultant thermal stresses need to be reduced to prevent twinning.
Salem, Jonathan A.↗
A multiphysics coupling framework for exascale simulation of fracture evolution in subsurface energy applications
Predicting the evolution of fractured media is challenging due to coupled thermal, hydrological, chemical and mechanical processes that occur over a broad range of spatial scales, from the microscopic pore scale to field scale. We present a software framework and scientific workflow that couples the pore scale flow and reactive transport simulator Chombo-Crunch with the field scale geomechanics solver in GEOS to simulate fracture evolution in subsurface fluid-rock systems. This new multiphysics coupling capability comprises several novel features. An HDF5 data schema for coupling fracture positions between the two codes is employed and leverages the coarse resolution of the GEOS mechanics solver which limits the size of data coupled, and is, thus, not taxed by data resulting from the high resolution pore scale Chombo-Crunch solver. The coupling framework requires tracking of both before and after coarse nodal positions in GEOS as well as the resolved embedded boundary in Chombo-Crunch. We accomplished this by developing an approach to geometry generation that tracks the fracture interface between the two different methodologies. The GEOS quadrilateral mesh is converted to triangles which are organized into bins and an accessible tree structure; the nodes are then mapped to the Chombo representation using a continuous signed distance function that determines locations inside, on and outside of the fracture boundary. The GEOS positions are retained in memory on the Chombo-Crunch side of the coupling. The time stepping cadence for coupled multiphysics processes of flow, transport, reactions and mechanics is stable and demonstrates temporal reach to experimental time scales. The approach is validated by demonstration of 9 days of simulated time of a core flood experiment with fracture aperture evolution due to invasion of carbonated brine in wellbore-cement and sandstone. We also demonstrate usage of exascale computing resources by simulating a high resolution version of the validation problem on OLCF Frontier.
97 MATHEMATICS AND COMPUTING↗
Basic failure mechanisms in advanced composites
The fundamental failure mechanisms which result from the interaction of thermal cycling and mechanical loading of carbon-epoxy composites were studied. This work was confined to epoxy resin uniderictionally reinforced with HTS carbon fibers, and consists of first identifying local fiber, matrix and interface failure mechanisms using the model composite specimen containing a small number of fibers so that optical techniques can be used for characterization. After the local fracture process has been established for both mechanical loading and thermal cycling, engineering composite properties and gross fracture modes are then examined to determine how the local events contribute to real composite performance. Flexural strength in high fiber content specimens shows an increase in strength with increased thermal cycling. Similar behavior is noted for 25 v/o material up to 200 cycles; however, there is a drastic reduction after 200 cycles indicating a major loss of integrity probably through the accumulation of local cleavage cracks in the tensile region.
Mazzio, V. F.↗
EGS Reservoir Modeling for Developing Geothermal District Heating at Cornell University: Preprint
Cornell University is pursuing development of an enhanced geothermal system (EGS) for providing heating to its main campus in Upstate New York. A ~10,000 ft (~3 km) deep vertical observation well ("CUBO") was drilled in 2022 to characterize the subsurface using wellbore logging, borehole imaging, fluid sampling, mini-frac tests, coring and drill cutting analysis. Down-hole temperatures measured at 3 km depth are about 80 degrees C, sufficiently high for direct-use heating. The well drilled through generally low porosity and low permeability Paleozoic sedimentary formations and into metamorphic basement rock, encountered at about 9,400 ft depth. Leveraging subsurface data obtained through CUBO, we investigated technical feasibility and design requirements of a doublet well system with horizontal laterals connected to a fracture network created through hydraulic fracturing. The EGS reservoir is sized to provide a nominal heat output in the range 5 to 10 MWth of continuous heating over a 15 year-lifetime with limited thermal drawdown. We applied the Gringarten Multiple parallel fracture model, the Cornell Discrete Fracture Simulator FOXFEM and the commercial simulator ResFrac to estimate required heat transfer area and design a potential hydraulic stimulation treatment. Reservoir simulations indicate that, depending on fluid flow rate and injection temperature, 2 to 3 km2 of effective fracture heat transfer area is required to supply the target heat output of 5 to 10 MWth over 15 years.
district heating↗
EGS Reservoir Modeling for Developing Geothermal District Heating at Cornell University
Cornell University is pursuing development of an enhanced geothermal system (EGS) for providing heating to its main campus in Upstate New York. A ~10,000 ft (~3 km) deep vertical observation well ('CUBO') was drilled in 2022 to characterize the subsurface using wellbore logging, borehole imaging, fluid sampling, mini-frac tests, coring and drill cutting analysis. Down-hole temperatures measured at 3 km depth are about 80 degrees C, sufficiently high for direct-use heating. The well drilled through generally low porosity and low permeability Paleozoic sedimentary formations and into metamorphic basement rock, encountered at about 9,400 ft depth. Leveraging subsurface data obtained through CUBO, we investigated technical feasibility and design requirements of a doublet well system with horizontal laterals connected to a fracture network created through hydraulic fracturing. The EGS reservoir is sized to provide a nominal heat output in the range 5 to 10 MWth of continuous heating over a 15 year-lifetime with limited thermal drawdown. We applied the Gringarten Multiple parallel fracture model, the Cornell Discrete Fracture Simulator FOXFEM and the commercial simulator ResFrac to estimate required heat transfer area and design a potential hydraulic stimulation treatment. Reservoir simulations indicate that, depending on fluid flow rate and injection temperature, 2 to 3 km2 of effective fracture heat transfer area is required to supply the target heat output of 5 to 10 MWth over 15 years.
district heating↗
Implications of post-processing induced microstructural changes on the deformation and fracture response of additively manufactured Ti–6Al–4V
Ti–6Al–4V parts fabricated via electron beam melting (EBM) powder bed fusion are often subjected to hot isostatic pressing below the β-transus temperature to mitigate defects. During which the pressure aids in pore closure and the thermal exposure results in coarsening of α phase while retaining the columnar prior-β phase grain morphology present in the as-fabricated condition. The same post-processing treatment can also be carried out above β-transus temperature which is an effective way to modify both the grain morphology and the associated α textures. Here, the objective of this work is to correlate thermally induced microstructural changes to the deformation and fracture response of the EBM processed Ti–6Al–4V. To this end, we have carried out both sub-transus and super-transus heat-treatments of the as-fabricated material. The mechanical response of the as-fabricated and all heat-treated materials are characterized by in-situ tensile tests under a high-resolution digital optical microscope. This enabled us to capture large-scale panoramic images of the deforming microstructure, and overcome the trade-off between the image resolution and the field of view during in-situ experiments. The series of images captured throughout the imposed deformation are subsequently used to perform microstructure-based digital image correlation to measure microstructural-scale strains over a large area. The results of the in-situ tests together with detailed fractographic analyses are then used to elucidate how the heterogeneous deformation spanning over multiple microstructural length-scales, for example, at the scale of lamellae, colonies of lamellae and grain boundaries, affect the overall deformation and fracture response of the post-processed materials.
36 MATERIALS SCIENCE↗
Probabilistic Fatigue Life Analysis of High Density Electronics Packaging
The fatigue of thin film metal interconnections in high density electronics packaging subjected to thermal cycling has been evaluated using a probabilistic fracture mechanics methodology. This probabilistic methodology includes characterization of thin film stress using an experimentally calibrated finite element model and simulation of flaw growth in the thin films using a stochastic crack growth model.
thermal cycling fatigue of thin film metal interco↗
Gas Production from Hot Water Circulation through Hydraulic Fractures in Methane Hydrate-Bearing Sediments: THC-Coupled Simulation of Production Mechanisms
Methane hydrates, widely found in permafrost and deep marine sediments, have great potential as a future energy 6 source. Conventional production schemes perform poorly for challenging hydrate reservoirs with low permeability. We propose an 7 efficient production scheme by combining hydraulic fracturing from horizontal wells and hot water circulation through fractures. A 8 fully coupled thermo-hydro-chemical (THC) model is developed to simulate the key physical processes during gas production from 9 a hydrate reservoir representative of typical geological settings in Shenhu, South China Sea. We found that the gas production 10 process has two distinct stages divided by thermal breakthrough: a relatively short prebreakthrough stage and a postbreakthrough 11 stage yielding stable gas production. Heat advection along and near the hydraulic fracture dominates the prebreakthrough stage, 12 whereas conduction-driven thermal recovery in the volume around fractures dominates the postbreakthrough stage. We identified 13 that the steady-state injection temperature has a strong effect on the performance of the proposed scheme while the fluid mass 14 circulation rate has a moderate impact beyond a threshold. The proposed scheme proves to be efficient and robust over a range of 15 reservoir conditions with respect to initial hydrate saturation and intrinsic permeability, including their spatial heterogeneities, 16 thereby offering a promising solution for challenging reservoir conditions.
gas hydrate, fracture flow, gas production, numeri↗
Contact thermal shock test of ceramics
A novel quantitative thermal shock test of ceramics is described. The technique employs contact between a metal-cooling rod and hot disk-shaped specimen. In contrast with traditional techniques, the well-defined thermal boundary condition allows for accurate analyses of heat transfer, stress, and fracture. Uniform equibiaxial tensile stresses are induced in the center of the test specimen. Transient specimen temperature and acoustic emission are monitored continuously during the thermal stress cycle. The technique is demonstrated with soda-lime glass specimens. Experimental results are compared with theoretical predictions based on a finite-element method thermal stress analysis combined with a statistical model of fracture. Material strength parameters are determined using concentric ring flexure tests. Good agreement is found between experimental results and theoretical predictions of failure probability as a function of time and initial specimen temperature.
Rogers, W. P.↗
Thermo-Mechanical Phase-Field Modeling of Fracture in High-Burnup UO2 Fuels Under Transient Conditions
This study presents a novel multiphysics phase-field fracture model to analyze high-burnup uranium dioxide (UO2) fuel behavior under transient reactor conditions. Fracture is treated as a stochastic phase transition, which inherently accounts for the random microstructural effects that lead to variations in the value of fracture strength. Moreover, the model takes into consideration the effects of temperature and burnup on thermal conductivity. Therefore, the model is able to predict crack initiation, propagation, and complex morphologies in response to thermal gradients and stress distributions. Several simulations were conducted to investigate the effects of operational and transient conditions on fracture behavior and the resulting cracking patterns. High-burnup fuels exhibit reduced thermal conductivity, elevating temperature gradients and resulting in extensive radial and circumferential cracks. Transient heating rates and temperatures significantly affect fracture patterns, with higher heating rates generating steeper gradients and more irregular crack trajectories. This approach provides critical insights into fuel integrity during accident scenarios and supports the safety evaluation of extended burnup limits.
Chemistry↗