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At least 253 records · Page 14

Mechanical properties of lunar regolith and lunar soil simulant

Through the Surveyor 3 and 7, and Apollo 11-17 missions a knowledge of the mechanical properties of Lunar regolith were gained. These properties, including material cohesion, friction, in-situ density, grain-size distribution and shape, and porosity, were determined by indirect means of trenching, penetration, and vane shear testing. Several of these properties were shown to be significantly different from those of terrestrial soils, such as an interlocking cohesion and tensile strength formed in the absence of moisture and particle cementation. To characterize the strength and deformation properties of Lunar regolith experiments have been conducted on a lunar soil simulant at various initial densities, fabric arrangements, and composition. These experiments included conventional triaxial compression and extension, direct tension, and combined tension-shear. Experiments have been conducted at low levels of effective confining stress. External conditions such as membrane induced confining stresses, end platten friction and material self weight have been shown to have a dramatic effect on the strength properties at low levels of confining stress. The solution has been to treat these external conditions and the specimen as a full-fledged boundary value problem rather than the idealized elemental cube of mechanics. Centrifuge modeling allows for the study of Lunar soil-structure interaction problems. In recent years centrifuge modeling has become an important tool for modeling processes that are dominated by gravity and for verifying analysis procedures and studying deformation and failure modes. Centrifuge modeling is well established for terrestrial enginering and applies equally as well to Lunar engineering. A brief review of the experiments is presented in graphic and outline form.

Steven W Perkins↗

Mechanical Characterization and Micromechanical Modeling of Woven Carbon/Copper Composites

The present investigation examines the in-plane mechanical behavior of a particular woven metal matrix composite (MMC); 8-harness (8H) satin carbon/copper (C/Cu). This is accomplished via mechanical testing as well as micromechanical modeling. While the literature is replete with experimental and modeling efforts for woven and braided polymer matrix composites, little work has been done on woven and braided MMC's. Thus, the development and understanding of woven MMC's is at an early stage. 8H satin C/Cu owes its existence to the high thermal conductivity of copper and low density and thermal expansion of carbon fibers. It is a candidate material for high heat flux applications, such as space power radiator panels. The experimental portion of this investigation consists of monotonic and cyclic tension, compression, and Iosipescu shear tests, as well as combined tension-compression tests. Tests were performed on composite specimens with three copper matrix alloy types: pure Cu, Cu-0.5 weight percent Ti (Cu-Ti), and Cu-0.7 weight percent Cr (Cu-Cr). The small alloying additions are present to promote fiber/matrix interfacial bonding. The analytical modeling effort utilizes an approach in which a local micromechanical model is embedded in a global micromechanical model. This approach differs from previously developed analytical models for woven composites in that a true repeating unit cell is analyzed. However, unlike finite element modeling of woven composites, the geometry is sufficiently idealized to allow efficient geometric discretization and efficient execution.

Bednarcyk, Brett A.↗

Extrapolating Accelerated UV Weathering Data: Perspective From PVQAT Task Group 5 (Presentation)

Taskgroup 5 (TG5) is concerned with a accelerated aging standard incorporating factors including ultraviolet radiation, temperature, and moisture. Separate experiments are being conducted in support of a test standard via the regional sub-groups in Asia, Europe, and the United States. The authors will describe the objectives and timeline for the TG5 interlaboratory study being directed out of the USA. Qualitative preliminary data from the experiment is presented. To date, the encapsulation transmittance experiment has: replicated behaviors of fielded materials (including specimen location- and formulation additive-specific discoloration); demonstrated coupling between UV aging and temperature; demonstrated that degradation in EVA results from UV- aging; and obtained good qualitative comparison between Xe and UVA-340 sources for EVA. To date, the encapsulation adhesion experiment (using the compressive shear test to quantify strength of attachment) has demonstrated that attachment strength can decrease drastically (>50%) with age; however, early results suggest significant factor (UV, T, RH) dependence. Much remains to be learned about adhesion.

14 SOLAR ENERGY↗

Further Studies of Materials Compatibility in High-Test Hydrogen Peroxide

Assessment of the compatibility of high-test hydrogen peroxide (HTP) with materials, in particular new materials such as composites, is critical to the development of new propulsion systems meeting requirements of reduced cost and environmental impact. While compatibility with HTP has been addressed previously, newer materials were not considered. The focus of this project was to develop a scheme for evaluation of HTP with all materials. In the previous summer, methods were developed for production of HTP on site, and preliminary steps were taken to evaluate materials. Methods investigated this summer have included accelerated aging by heating, coupled with assay of concentration and stabilization loss, observation of reactivity by means of Isothermal Microcalorimetry, and evaluation of changes to the materials by Short Beam Shear testing and by Photoacoustic-Fourier Transform Infrared Spectroscopy. Various metals, polymers, and composites were examined in this study.

Gostowski, R.↗

Improved Mobility Control for Carbon Dioxide (CO{sub 2}) Enhanced Oil Recovery Using Silica-Polymer-Initiator (SPI) Gels

SPI gels are multi-component silicate based gels for improving (areal and vertical) conformance in oilfield enhanced recovery operations, including water-floods and carbon dioxide (CO{sub 2}) floods, as well as other applications. SPI mixtures are like-water when pumped, but form light up to very thick, paste-like gels in contact with CO{sub 2}. When formed they are 3 to 10 times stronger than any gelled polyacrylamide gel now available, however, they are not as strong as cement or epoxy, allowing them to be washed / jetted out of the wellbore without drilling. This DOE funded project allowed 8 SPI field treatments to be performed in 6 wells (5 injection wells and 1 production well) in 2 different fields with different operators, in 2 different basins (Gulf Coast and Permian) and in 2 different rock types (sandstone and dolomite). Field A was in a central Mississippi sandstone that injected CO{sub 2} as an immiscible process. Field B was in the west Texas San Andres dolomite formation with a mature water-alternating-gas miscible CO{sub 2} flood. Field A treatments are now over 1 year old while Field B treatments have only 4 months data available under variable WAG conditions. Both fields had other operational events and well work occurring before/ during / after the treatments making definitive evaluation difficult. Laboratory static beaker and dynamic sand pack tests were performed with Ottawa sand and both fields’ core material, brines and crude oils to improve SPI chemistry, optimize SPI formulations, ensure SPI mix compatibility with field rocks and fluids, optimize SPI treatment field treatment volumes and methods, and ensure that strong gels set in the reservoir. Field quality control procedures were designed and utilized. Pre-treatment well (surface) injectivities ranged from 0.39 to 7.9 MMCF/psi. The SPI treatment volumes ranged from 20.7 cubic meters (m{sup 3}, 5460 gallons/ 130 bbls) to 691 m{sup 3} (182,658 gallons/ 4349 bbls). Various size and types of chemical/ water buffers before and after the SPI mix ensured that pre-gelled SPI mix got out into the formation before setting into a gel. SPI gels were found to be 3 to 10 times stronger than any commercially available cross-linked polyacrylamide gels based on Penetrometer and Bulk Gel Shear Testing. Because of SPI’s unique chemistry with CO{sub 2}, both laboratory and later field tests demonstrated that multiple, smaller volume SPI treatments maybe more effective than one single large SPI treatment. CO{sub 2} injectivities in injection well in both fields were reduced by 33 to 70% indicating that injected CO{sub 2} is now going into new zones. This reduction has lasted 1+ year in Field A. Oil production increased and CO{sub 2} production decreased in 5 Field A production wells, offsets to Well #1 injector, for a total of about 2,250 m{sup 3} (600,000 gallons/ 14,250 bbls) of incremental oil production- a $140 / SPI bbl return. Treated marginal production well, Field A Well #2, immediately began showing increased oil production totaling 238 m{sup 3} (63,000 gallons/ 1500 BBLs) over 1 year and an immediate 81% reduced gas-oil ratio.

01 COAL, LIGNITE, AND PEAT↗

Experimental Characterization and Micromechanical Modeling of Woven Carbon/Copper Composites

The results of an extensive experimental characterization and a preliminary analytical modeling effort for the elastoplastic mechanical behavior of 8-harness satin weave carbon/copper (C/Cu) composites are presented. Previous experimental and modeling investigations of woven composites are discussed, as is the evolution of, and motivation for, the continuing research on C/Cu composites. Experimental results of monotonic and cyclic tension, compression, and Iosipescu shear tests, and combined tension-compression tests, are presented. With regard to the test results, emphasis is placed on the effect of strain gauge size and placement, the effect of alloying the copper matrix to improve fiber-matrix bonding, yield surface characterization, and failure mechanisms. The analytical methodology used in this investigation consists of an extension of the three-dimensional generalized method of cells (GMC-3D) micromechanics model, developed by Aboudi (1994), to include inhomogeneity and plasticity effects on the subcell level. The extension of the model allows prediction of the elastoplastic mechanical response of woven composites, as represented by a true repeating unit cell for the woven composite. The model is used to examine the effects of refining the representative geometry of the composite, altering the composite overall fiber volume fraction, changing the size and placement of the strain gauge with respect to the composite's reinforcement weave, and including porosity within the infiltrated fiber yarns on the in-plane elastoplastic tensile, compressive, and shear response of 8-harness satin C/Cu. The model predictions are also compared with the appropriate monotonic experimental results.

Bednarcyk, Brett A.↗

Multiphysics Lattice Discrete Particle Modeling (M-LDPM) for the Simulation of Shale Fracture Permeability

A three-dimensional multiphysics lattice discrete particle model (M-LDPM) framework is formulated to investigate the fracture permeability behavior of shale. The framework features a dual lattice system mimicking the mesostructure of the material and simulates coupled mechanical and flow behavior. The mechanical lattice model simulates the granular internal structure of shale, and describes heterogeneous deformation by means of discrete compatibility and equilibrium equations. The network of flow lattice elements constitutes a dual graph of the mechanical lattice system. A discrete formulation of mass balance for the flow elements is presented to model fluid flow along cracks and intact materials. The overall computational framework is implemented with a mixed explicit–implicit integration scheme and a staggered coupling method that makes use of the dual lattice topology enabling the seamless two-way coupling of the mechanical and flow behaviors. The proposed model is used for the computational analysis of shale fracture permeability behavior by simulating triaxial direct shear tests on Marcellus shale specimens under various confining pressures. The simulated mechanical response is calibrated against the experimental data, and the predicted permeability values are also compared with the experimental measurements. Moreover, the paper presents the scaling analysis of both the mechanical response and permeability measurements based on simulations performed on geometrically similar specimens with increasing size. The simulated stress strain curves reflect a significant size effect in the post-peak due to the presence of localized fractures. The scaling analysis of permeability measurements enables prediction of permeability for large specimens by extrapolating the numerical results of small ones.

58 GEOSCIENCES↗

A Self‐Healing System for Polydicyclopentadiene Thermosets

Self-healing offers promise for addressing structural failures, increasing lifespan, and improving durability in polymeric materials. Implementing self-healing in thermoset polymers faces significant manufacturing challenges, especially due to the elevated temperature requirements of thermoset processing. To introduce self-healing into structural thermosets, the self-healing system must be thermally stable and compatible with the thermoset chemistry. This article demonstrates a self-healing microcapsule-based system stable to frontal polymerization (FP), a rapid and energy-efficient manufacturing process with a self-propagating exothermic reaction (≈200 °C). A thermally latent Grubbs-type complex bearing two N-heterocyclic carbene ligands addresses limitations in conventional G2-based self-healing approaches. Under FP's elevated temperatures, the catalyst remains dormant until activated by a Cu(I) co-reagent, ensuring efficient polymerization of the dicyclopentadiene (DCPD) upon damage to the polyDCPD matrix. The two-part microcapsule system consists of one capsule containing the thermally latent Grubbs-type catalyst dissolved in the solvent, and another capsule containing a Cu(I) coagent blended with liquid DCPD monomer. Using the same chemistry for both matrix fabrication and healing results in strong interfaces as demonstrated by lap-shear tests. In an optimized system, the self-healing system restores the mechanical properties of the tough polyDCPD thermoset. Self-healing efficiencies greater than 90% via tapered double cantilever beam tests are observed.

36 MATERIALS SCIENCE↗

Degradation in photovoltaic encapsulation strength of attachment: Results of the first PVQAT TG5 artificial weathering study

Delamination of the encapsulant in photovoltaic (PV) module technology results in immediate optical loss and may enable subsequent corrosion or mechanical damage. The effects of artificial weathering were not previously known; therefore, an empirical study was performed to survey the factors most affecting adhesion, including the ultraviolet (UV) source (ie, Xe or fluorescent lamp[s]), the optical filters for the lamp, the chamber temperature, and the relative humidity. Natural weathering was also performed at locations, including the following: Golden, Colorado; Miami, Florida; Phoenix, Arizona; QiongHai, China; Riyadh, Saudi Arabia; and Turpan, China. Specimens were constructed using a laminated glass/poly (ethylene-co-vinyl acetate)/glass geometry. The compressive shear test (CST) was used to quantify the mechanical strength of attachment, taken as a proxy for adhesion. The fractography of select specimens (including cross-sectional optical microscopy) was used to verify the failure mode (delamination or decohesion). Additional analysis of the local solar spectrum as well as the specimen temperature was performed to interpret the results of natural weathering. The goals of this study include to identify the most significant stressors, clarify where strong coupling may occur between stressors, and validate accelerated test results relative to natural weathering. The importance of specimen conditioning (for moisture) and hygrometric degradation as well as the effects of UV degradation are identified in this paper.

14 SOLAR ENERGY↗

Surface engineering to enhance heat generation and joint strength in dissimilar materials AZ31 and DP590 ultrasonic welding

A multiscale simulation approach was developed and employed to optimize the sheet surface conditions for higher interfacial temperature and joint strength in ultrasonic welding of magnesium alloy AZ31 and dual-phase steel DP590. First, a mesoscale model was used to study the relationship between friction coefficient and surface roughness, which can be modified by various engineering methods. Then a macroscopic process model was employed to study the effects of surface roughness on heat generation, indicating that a temperature increase can be achieved with rougher surfaces on two sides of both DP590 and AZ31 sheets. Samples prepared by sanding and filing, as well as grinding, were first characterized for surface roughness and then welded under ultrasonic vibration. An infrared camera was used to measure temperatures in situ for model validation. Overall, lap shear test results for the welded joint showed that the joint strength can be improved by 10~25% using filing and round grinding methods as a result of the enhanced heat generation and mechanical interlocking on the interface.

42 ENGINEERING↗

Coupled thermal stress simulations of ductile tearing

Predictions for ductile tearing of a geometrically complex Ti-6Al-4V plate were generated using a Unified Creep Plasticity Damage model in fully coupled thermal stress simulations. Uniaxial tension and butterfly shear tests performed at displacement rates of 0.0254 and 25.4 mm/s were also simulated. Results from these simulations revealed that the material temperature increase due to plastic work can have a dramatic effect on material ductility predictions in materials that exhibit little strain hardening. Furthermore, this occurs because the temperature increase causes the apparent hardening of the material to decrease which leads to the initiation of deformation localization and subsequent ductile tearing earlier in the loading process.

36 MATERIALS SCIENCE↗

Adhesive and Cohesive Strength in FeB/Fe{sub 2}B Systems

In this work, FeB/Fe{sub 2}B systems were evaluated by the scratch test. The powder-pack boriding process was performed on the surface of AISI M2 steel. The mechanical parameters, such as yield stress and Young’s modulus of the boride layer, were obtained by the instrumented indentation technique. Residual stresses produced on the boride layer were estimated by using the x-ray diffraction (XRD) technique. The scratch test was performed in order to evaluate the cohesive/adhesive strength of the FeB/Fe{sub 2}B coating. In addition, a numerical evaluation of the scratch test on boride layers was performed by the finite element method. Maximum principal stresses were related to the failure mechanisms observed by the experimental scratch test. Shear stresses at the interfaces of the FeB/Fe{sub 2}B/substrate system were also evaluated. Finally, the results obtained provide essential information about the effect of the layer thickness, the residual stresses, and the resilience modulus on the cohesive/adhesive strength in FeB/Fe{sub 2}B systems.

36 MATERIALS SCIENCE↗

A review of technologies for welding magnesium alloys to steels

Here we review various state-of-the-art methods for welding magnesium alloys and steels using different joint configurations. Microstructural characterizations indicate that four microstructures may form at the Mg/steel interface after welding: unwelded gap, metal oxides, solid solutions, or intermetallic compounds. Reaction products at the Mg/steel interface vary with different welding methods, alloying elements in base materials, interlayers or coatings applied, and preparations of base material before welding. Regarding mechanical property characterization, (a) lap tensile shear testing for lap-welded and spot-welded joints, (b) tensile testing for butt-welded joints and (c) fatigue properties of lap-welded and spot-welded joints are summarized and compared, separately. Reaction products at the Mg/steel interface are correlated with mechanical properties. Finally, ways to enhance Mg/steel joint strength, such as introducing interlocking features during friction stir lap and butt welding, are discussed.

Wang, Tianhao↗

Parameter covariance and non-uniqueness in material model calibration using the Virtual Fields Method

Traditionally, material identification is performed using global load and displacement data from simple boundary-value problems such as uni-axial tensile and simple shear tests. More recently, however, inverse techniques such as the Virtual Fields Method (VFM) that capitalize on heterogeneous, full-field deformation data have gained popularity. In this work, we have written a VFM code in a finite-deformation framework for calibration of a viscoplastic (i.e. strain-rate dependent) material model for 304L stainless steel. Using simulated experimental data generated via finite-element analysis (FEA), we verified our VFM code and compared the identified parameters with the reference parameters input into the FEA. The identified material model parameters had surprisingly large error compared to the reference parameters, which was traced to parameter covariance and the existence of many essentially equivalent parameter sets. This parameter non-uniqueness and its implications for FEA predictions is discussed in detail. Lastly, we present two strategies to reduce parameter covariance – reduced parametrization of the material model and increased richness of the calibration data – which allow for the recovery of a unique solution.

304L stainless steel↗

CT scanning and flow measurements of shale fractures after multiple shearing events

A shearing apparatus was used in conjunction with a Hassler-style core holder to incrementally shear fractured shale cores while maintaining various confining pressures. Computed tomography scans were performed after each shearing event, and were used to obtain information on evolving fracture geometry. Fracture transmissivity was measured after each shearing event to understand the hydrodynamic response to the evolving fracture structure. The digital fracture volumes were used to perform laminar single phase flow simulations (local cubic law with a tapered plate correction model) to qualitatively examine small scale flow path variations within the altered fractures. Fractures were found to generally increase in aperture after several shear slip events, with corresponding transmissivity increases. Lower confining pressure resulted in a fracture more prone to episodic mechanical failure and sudden changes in transmissivity. Conversely, higher confining pressures resulted in a system where, after an initial setting of the fracture surfaces, changes to the fracture geometry and transmissivity occurred gradually. Flow paths within the fractures are largely controlled by the location and evolution of zero aperture locations. Lastly, a reduction in the number of primary flow pathways through the fracture, and an increase in their width, was observed during all shearing tests.

04 OIL SHALES AND TAR SANDS↗

From acetone fractionation to lignin-based phenolic and polyurethane resins

In this paper, acetone fractionation was used to increase the homogeneity of softwood kraft lignin for product development. The acetone soluble and insoluble fractions were analyzed in terms of elemental composition, chemical structure, and thermal properties. The phenolic hydroxyl content of the acetone soluble fraction increased by 24%. The acetone soluble fraction of kraft lignin was used to fully substitute phenol in phenolic resin formulation. The resulting formulated lignin-formaldehyde adhesive showed higher adhesion strength (4.3 MPa) compared to a lab formulated phenol-formaldehyde resin (3.4 MPa) with 100% wood failure after lap shear test. On the other hand, the acetone insoluble lignin fraction, which had 23% higher aliphatic hydroxyl content compared to the starting lignin, was used to entirely replace petroleum-based polyol in polyurethane resin formulation. Then a bio-derived solvent (dihydrolevoglucosenone, Cyrene) was used to dissolve the acetone insoluble lignin fraction to synthesize lignin-based polyurethane resin. Tailoring the structure of kraft lignin through solvent fractionation resulted in two fractions, which were used to replace 100% of two major petrochemicals (phenol and polyol) in the formulations of phenolic and PU resins, that would otherwise be challenging due to the heterogeneity of softwood kraft lignin.

36 MATERIALS SCIENCE↗

Biaxial steel plated concrete constitutive models for composite structures: Implementation and validation

The Steel-plated Concrete (SC) technique is an alternative construction technique with faster onsite construction speed, reduced construction time, and increased structural performance. Aiming to predict the force transfer mechanism of SC elements, an innovative constitutive model package is proposed by implementing experimental-based biaxial steel plate concrete models into the nonlinear finite element (FE) model “Membrane Model of SC (MM-CS).” First, the formulation and implementation of the MM-SC is illustrated in detail, including the equilibrium and compatibility equations and the implementation of constitutive models. Next, various experimental data of SC members are selected and simulated using the proposed MM-SC model. In this research, two types of structures, SC panels and framed SC shear walls, and three types of loading conditions, including uniaxial compression, pure shear, and combined axial-flexural-shear tests, are analyzed respectively. Good agreements were obtained between the reported results and the FE simulation results in terms of yield capacity and ultimate capacity, proving the reliability of the implemented analytical constitutive material models and the biaxial membrane model formulations.

42 ENGINEERING↗

Evaluation of intermetallic compound layer at aluminum/steel interface joined by friction stir scribe technology

Heat input and high strain rate deformation during friction stir welding of aluminum and steel resulted in the diffusion-based formation of a Fe x Al y intermetallic compound (IMC) layer. Compared with conventional friction stir welding tools, a friction stir scribe tool can reduce heat input significantly limiting the IMC layer thickness (~100–750 nm). Friction stir scribe joined lap joints fractured either through the welded interface or within the base aluminum alloy on the loading side, depending on IMC layer thickness during tensile lap shear testing. In addition, a modified effective heat of formation model predicted that Al 13 Fe 4 formed first at aluminum/steel interface and, during welding process, was substituted by Al 5 Fe 2 with local silicon enrichment, which was verified via microstructural characterization.

36 MATERIALS SCIENCE↗