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Formation of Insoluble Organic Material from the Ultraviolet Irradiation of Laboratory Ice Photolysis Residues

We present preliminary results from the study of ice photolysis residues which were exposed to ultraviolet (UV)/extreme UV (EUV) photon radiation. The residues were produced from the simultaneous deposition and UV irradiation of ice mixtures of astrophysical interest (H2O, CH3OH, CO, NH3, without/with N2 and/or O2, and without/with small quantities of aromatic compounds) at 15–20 K using an H2 lamp, which emits 10.2-eV (121.6 nm) Lyman-α photons and a continuum at 7.5–8 eV (155–165 nm). After warm-up to room temperature and subsequent sublimation of volatile compounds, the refractory materials (residues) recovered at room temperature were analyzed with infrared (IR) microscopy and then further irradiated with UV/EUV photons at a synchrotron facility, on a beamline providing a broad-band photon beam in the 4–45-eV range with a ~1016 photons s-1 flux.2 The residues were UV/EUV irradiated with increasing photon doses ranging from ~1018 to ~1021 photons, i.e., covering 4 orders of magnitude and relevant to those experienced by ice-coated grains in the protosolar nebula.1. After UV/EUV irradiation, residues were analyzed with IR microscopy and the data compared to those before irradiation to identify changes in chemical composition as a function of the photon dose. UV/EUV-irradiated residues were also analyzed with other techniques such as nanoscale secondary-ion mass spectrometry (nanoSIMS) to the study the changes in isotopic composition, and scanning transmission electron microscopy to look at variations in structure and C bonding distribution. Results will be compared with data from extraterrestrial materials, in particular, meteoritic insoluble organic material (IOM) and interplanetary dust particles (IDPs).

Ices↗
DOE OSTI2012

A Residual Monte Carlo Method for Spatially Discrete, Angularly Continuous Radiation Transport

Residual Monte Carlo provides exponential convergence of statistical error with respect to the number of particle histories. In the past, residual Monte Carlo has been applied to a variety of angularly discrete radiation-transport problems. Here, we apply residual Monte Carlo to spatially discrete, angularly continuous transport. By maintaining angular continuity, our method avoids the deficiencies of angular discretizations, such as ray effects. For planar geometry and step differencing, we use the corresponding integral transport equation to calculate an angularly independent residual from the scalar flux in each stage of residual Monte Carlo. We then demonstrate that the resulting residual Monte Carlo method does indeed converge exponentially to within machine precision of the exact step differenced solution.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2012

Residual Stresses in 21-6-9 Stainless Steel Warm Forgings

Forging residual stresses are detrimental to the production and performance of derived machined parts due to machining distortions, corrosion drivers and fatigue crack drivers. Residual strains in a 21-6-9 stainless steel warm High Energy Rate Forging (HERF) were measured via neutron diffraction. The finite element analysis (FEA) method was used to predict the residual stresses that occur during forging and water quenching. The experimentally measured residual strains were used to calibrate simulations of the three-dimensional residual stress state of the forging. ABAQUS simulation tools predicted residual strains that tend to match with experimental results when varying yield strength is considered.

Everhart, Wesley A.↗
DOE OSTI2020

Distribution Development for Residual Inventory at the New York West Valley Site - 20400

The New York State Energy Research and Development Authority (NYSERDA) is the owner of the Western New York Nuclear Service Center (WNYNSC), a 1,351 ha site located approximately 48 km south of Buffalo, New York. In 1962, Nuclear Fuel Services, Inc. (NFS) entered into Agreements with the Atomic Energy Commission and New York State to construct the first commercial reprocessing plant of nuclear fuel in the United States. NFS, a private company, built and operated the spent fuel reprocessing plant and waste disposal facilities, processing 640 Mg of spent nuclear fuel from 1966 to 1972 under an Atomic Energy Commission license. Nuclear fuel reprocessing operations ended in 1972 and never reopened, leaving behind radioactive and chemical wastes. Operations led to contamination in a number of facilities and locations. Some of that contamination has migrated from waste disposal zones to other layers, formations, and features on and off the WNYNSC. Phase I decommissioning activities are ongoing and involve the removal of a number of areas and structures that have been associated with contamination. The purpose of this work is to outline the approach for characterizing contamination not associated with disposed wastes, contaminated structures, or specific releases. In this work, the term, residual radiological activity, is used to describe environmental contamination that exists subsequent to the completion of Phase I decommissioning activities, that is not associated with disposed wastes, contaminated structures, or specific releases. Contamination from the Site was quantified relative to data that characterize the concentrations of radionuclides that exist in background. Background concentrations are those present in the area but having no influence from Site related activities. The existence of residual radiological activity that is elevated relative to background has the potential to contribute to future risks to human health and the environment. As a consequence, the residual inventory information is used to inform the West Valley Probabilistic Performance Assessment (PPA) model to characterize potential future risks to human health and the environment. The centralized West Valley Data Management System (DMS) was the source of information for the data assembled in this analysis. The DMS is a fairly large compilation consisting of thousands of records from investigation studies, with sample dates ranging from 1990 to present. Samples from monitoring wells, boreholes, geoprobe studies, surface water, surface soils, storm water outfalls, ventilation stack filters, plant and animal tissues, and more are included in the DMS. Results are typically reported in units of activity per unit volume. For the purpose of the analyses presented here, all results were converted into consistent units of pCi per unit volume. Since 1990, data have been collected from various locations across the WNYNSC at different times with varying frequency over the course of several decades. As a consequence, a number of potential issues can arise with respect to the assembly of a dataset that is deemed adequate for the characterization of residual radiological activity. These issues were assessed and resolved to the extent possible through careful consideration of the properties of the distributions. The intent was to use data which characterize the current state of the Site. Radionuclides can be designated to one of several groups depending on their origin. In this work the groups considered were 1) Naturally Occurring Radioactive Material (NORM), 2) fallout, and 3) Other (including power plant, medical research, etc). This grouping is a useful construct with respect to the interpretation of fixed laboratory results. For example, NORM radionuclides that exist within a decay chain should have approximately equivalent distributions of concentrations if they are representative of background conditions. Insights such as these can be used as a check to identify sample results that need to be further investigated or omitted due to issues associated with reported results from fixed laboratory analyses. This type of analysis provided a foundation for the assessment of the adequacy of sample results for use in subsequent components of an assessment. The general process for the assessment of residual radiological contamination at the Site consists of a sequence of several steps. First, for each analyte, several statistical tests were performed to assess the weight of evidence against the null hypothesis that the mean of the distribution of concentrations was equal to zero. If the mean of the distribution of concentrations for a given radionuclide was not found to be greater than zero, then it was removed from consideration as a component of the residual radiological contamination. If there was significant evidence to reject the hypothesis of the mean being equal to zero, the second step was to compare the distribution of the data from the Site to that of the corresponding background. A suite of tests was used to compare the distributions of the site and background data. The results of these tests were collectively used to determine if site data are elevated relative to background. The third step was to develop distributions using a Bayesian framework to characterize the distribution of mean of the increment present above background for each of the radionuclides. The Bayesian model implemented allowed for the comparison of site-specific records to background concentrations to better approximate contamination attributed to the Site. A final screening step was employed for radionuclides that exceed background. This screening step compared 95% upper confidence limits (UCLs) from the increment distribution developed in the previous step to the risk screening levels. This approach yields a list of analytes that were determined to be elevated relative to background.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

316 stainless steel↗
DOE OSTI2022

Why Is It So Challenging to Measure Residual Stresses ?

Abstract Background Residual stresses have a “hidden” character because they exist in a material without the presence of any external loads. They cannot easily be added or subtracted in a quantified manner, as is done when measuring applied stresses, and so are much more challenging to measure. Objective The objective here is to identify and describe the various features that make residual stress measurement methods challenging and to consider the ways that these challenges can be addressed in practice. Methods Various of the most common residual stress measurements methods are considered and the challenges associated with them are identified and classified. Results Five major challenges for residual stress measurements, and the approaches used for their resolution, are identified. Conclusions Despite the various challenges that need to be overcome, residual stress measurements can be successfully undertaken in practice. The most significant feature for success is a highly skilled and knowledge practitioner.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of Multi-Axial Loading on Residual Strain Tensor for 12L14 Steel Alloy

Evaluating the state of residual strain or stress is critically important for structural materials and for reliable design of complex shape components that need to function in extreme environment subjected to large thermo-mechanical loading. When residual stress state is superposed to external loads, it can lead to reduction or increase in failure strength. Past diffraction studies for evaluating the residual strain state involved measuring lattice spacings in three orthogonal directions and do not often correspond to principal directions. To completely resolve the state of strain at a given location, a full strain tensor must be determined. This is especially important when characterizing materials or metallic components exposed to biaxial or complex loading. Neutron diffraction at the second Generation Neutron Residual Stress Facility (NRSF2) at Oak Ridge National Laboratory is used in this study to measure strain tensors associated with different modes of stress path. Hollow cylinder steel samples with 2 mm wall thickness are subjected to either pure axial extension or pure torsion to simulate multi-axial loading conditions. A virgin sample that is not subjected to any deformation, but subjected to identical manufacturing conditions and machining steps involved to obtain hollow cylinder geometry is used for obtaining reference d-spacing for given hkl planes at target spatial location(s). The two samples which are subjected to either pure tension or torsion are loaded to a deformation state that corresponded to equal amount of octahedral shear strain which is an invariant. This procedure is used so that a basis for comparison between the two samples can be made to isolate the stress path effects. A 2-circle Huber orienter is used to obtain strain measurements on identical gauge volume at a series of chi and psi values. The residual state of stress tensor corresponding to ex situ (upon unloading) conditions is presented for three lattice planes (211, 110, 200) for a bcc ferritic system exposed to tension and pure torsion.

HB-2B↗
DOE OSTI2017

Influences of Processing and Fatigue Cycling on Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

Oxidation and corrosion can attack superalloy disk surfaces exposed to increasing operating temperatures in some turbine engine environments. Any potential protective coatings must also be resistant to harmful fatigue cracking during service. The objective of this study was to investigate how residual stresses evolve in one such coating. Fatigue specimens of a powder metallurgy-processed disk superalloy were coated with a NiCrY coating, shot peened, and then subjected to fatigue in air at room and high temperatures. The effects of this processing and fatigue cycling on axial residual stresses and other aspects of the coating were assessed. While shot peening did induce beneficial compressive residual stresses in the coating and substrate, these stresses relaxed in the coating with subsequent heating. Several cast alloys having compositions near the coating were subjected to thermal expansion and tensile stress relaxation tests to help explain this response of residual stresses in the coating. For the coated fatigue specimens, this response contributed to earlier cracking of the coating than for the uncoated surface during long intervals of cycling at 760 °C. Yet, substantial compressive residual stresses still remained in the substrate adjacent to the coating, which were sufficient to suppress fatigue cracking there. The coating continued to protect the substrate from hot corrosion pitting, even after fatigue cracks initiated in the coating.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Evolution of Residual Stress and Distortion of Cold-Rolled Bearing Ring from Annealing to Quenched-Tempered Heat Treatment

This study investigates the correlation between the residual stress and distortion behavior of a cold-rolled ring from the annealing to quenching-tempering (QT) process. Due to the cold-rolled process, the external periphery of the bearing ring experiences a compressive residual stress. To relieve the residual stress, cold-rolled rings are annealed at 700 °C which is higher than the starting temperature of recrystallization. When cold-rolled rings are annealed at 700 °C for 15 min, the compressive residual stress is reduced to zero and the outer diameter of the annealed ring becomes larger than that of a non-annealed sample, which is unrelated to annealing time. Simultaneously, the roundness and taper deviation do not obviously change compared with those of non-annealed sample. The stress relaxation during the annealing process was attributed to the recovery and recrystallization of ferrite. Annealing has a genetic influence on the following QT heat treatment, wherein the lowest residual stress is in the non-annealed cold-rolled ring. From the annealing to QT process, the deviation of the outer diameter, roundness, and taper increased with annealing time, a large extend than that of non-annealed samples.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Investigation of the Effect of Residual Stress Gradient on the Wear Behavior of PVD Thin Films

The control of residual stresses has been seldom investigated in multilayer coatings dedicated to improvement of wear behavior. Here, we report the preparation and characterization of superposed structures composed of Cr, CrN and CrAlN layers. Nano-multilayers CrN/CrAlN and Cr/CrN/CrAlN were deposited by Physical Vapor Deposition (PVD) onto Si (100) and AISI4140 steel substrates. The Cr, CrN and CrAlN monolayers were developed with an innovative approach in PVD coatings technologies corresponding to deposition with different residual stresses levels. Composition and wear tracks morphologies of the coatings were characterized by scanning electron microscopy, high-resolution transmission electron microscopy, atomic force microscopy, x-ray photoelectron spectroscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction and 3D-surface analyzer. The mechanical properties (hardness, residual stresses and wear) were investigated by nanoindentation, interferometry and micro-tribometry (fretting-wear tests). Observations suggest that multilayer coatings are composed mostly of nanocrystalline. The residual stresses level in the films has practically affected all the physicochemical and mechanical properties as well as the wear behavior. Consequently, it is demonstrated that the coating containing moderate stresses has a better wear behavior compared to the coating developed with higher residual stresses. The friction contact between coated samples and alumina balls shows also a large variety of wear mechanisms. In particular, the abrasive wear of the coatings was a combination of plastic deformation, fine microcracking and microspallation. The application of these multilayers will be wood machining of green wood.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Residual Stresses in Explosively Welded Plates Made of Titanium Grade 12 and Steel with Interlayer

Distributions of residual stress components in explosively welded three-layer plate composed of titanium Grade 12, titanium Grade 1 and SA516 Grade 70 steel are investigated in this paper. The study applied the sectioning and the hole-drilling strain gage methods for residual stress measurement. The results have shown an inhomogeneous residual stress distribution, approximated by fourth-order polynomial along the thickness of a three-layer plate. Biaxial compressive residual stress state is observed in titanium Grade 12 and Grade 1 layers which change to tensile type in the vicinity of the interface between titanium Grade 1 and steel. Microstructure observation reveals the presence of the adiabatic shear bands in titanium Grade 12 layer at the interface with titanium Grade 1 interlayer. The observed distribution of residual stress components is justified by the occurrence of the shock wave phenomena.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Micro-slotting Residual Stress Measurement Technique for Understanding Fatigue Performance of Open-Hole Ti-6Al-4V Samples

Micro-slotting, a microscale relaxation residual stress measurement technique, has been shown in recent years to be a reliable method for measuring local residual stresses in metallic materials. This study demonstrates the unique application of the micro-slotting residual stress measurement technique for measuring near-edge tangential residual stresses around cold-expanded holes in Ti-6Al-4V plates. Knowledge of the near-edge elastic strains induced by the hole processing, in combination with plastic strain information obtained using electron backscatter diffraction, allowed for interpretation of fatigue life differences and crack growth behavior between the as-drilled and cold-expanded conditions. The similar crack initiation lives of the as-drilled and cold-expanded open-hole coupons were attributed to the similar elastic and plastic strains present at the hole edges. The subsequent crack growth resistance observed for the cold-expanded holes was a result of the large compressive residual stress region induced by cold expansion.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Very High-Cycle Fatigue Properties and Residual Stress Relaxation of Micro-shot-Peened EA4T Axle Steel

In this paper, EA4T alloy railway axle steel was shot peened with steel balls and ceramic balls with a diameter of 50 μm, and 10{sup 9}-cycle fatigue tests of unpeened and peened specimens were carried out. The fatigue properties and the surface compression residual stress relaxation processes were investigated. The results of surface fracture observation indicated that all the cracks initiated from the surface, and both peened and unpeened specimens have conventional fatigue limits in the very high-cycle fatigue regime. Moreover, compared with unpeened (UP) specimens, the fatigue limits were improved by 31 and 28% for ceramic shot-peened (CSP) and steel shot-peened (SSP) specimens, respectively. The improvement of fatigue limit is related to the surface compressive residual stresses (SCRS) and the surface-hardened layer. The SCRS and full-width half-maximum (FWHM) values during the relaxation processes have been analyzed. At stress amplitudes lower than the cyclic yield strength, the residual stress of SSP specimens relaxed quickly in the first loading cycle and then remained stable, while the residual stress of CSP specimens relaxed quickly in the first loading cycle and relaxed slowly afterward, then remained stable. For all SSP and CSP specimens with applied stress amplitudes larger than the cyclic yield strength, the residual stress relaxed quickly in the initial cycles, and then remained stable after the first loading cycle.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Influence of Residual Stress on Fatigue Crack Growth Rates in Stainless Steel Processed by Different Additive Manufacturing Methods

The properties and microstructure of Type 304L stainless steel produced by two additive manufacturing (AM) methods—directed energy deposition (DED) and powder bed fusion (PBF)—are evaluated and compared. Localized heating and steep temperature gradients of AM processes lead to significant residual stress and distinctive microstructures, which may be process-specific and influence mechanical behavior. Test data show that materials produced by DED and PDF have small differences in tensile strengths but clear differences in residual stress and microstructural features. Measured fatigue crack growth rates (FCGRs) for cracks propagating parallel to and perpendicular to the build directions differ between the two AM materials. To separate the influences of residual stress and microstructure, K-control test procedures with decreasing and constant stress intensity factor ranges are used to measure FCGRs in the near-threshold regime (crack growth rates ≤ 1 × 10 −8 m/cycle). Residual stress is quantified by the residual stress intensity factor, K res , measured by the online crack compliance method. Correcting the FCGR data for differences in K res brings results for specimens of the two AM materials into agreement with each other and with results for wrought specimens, when the latter are corrected for crack closure. Differences in microstructure and tensile strength have an insignificant influence on FCGRs in these tests.

additive manufacturing↗
DOE OSTI2023

Microstructure and Residual Stress in Functionally Graded 316L Stainless Steel/Inconel 625 Alloys Fabricated by Direct Energy Deposition

Functionally graded materials (FGMs) provide a unique solution to combine distinct properties within a single component to enhance its overall performance. Understanding the microstructure and residual stress distribution is particularly important as the material dissimilarity in FGMs can result in high residual stress that affects the mechanical integrity of structural components. Here, this work aims to study the microstructure and residual stress of additively manufactured FGMs and the effects of isothermal annealing. In this study, 316L stainless steel/Inconel 625 FGMs were built by direct energy deposition, and characterized by optical and electron microscopy as well as synchrotron-based X-ray diffraction. Our study reveals that thermal annealing at 500°C for 3 h has minimal effects on the microstructure and chemistry of the graded materials, but effectively relieves the residual stress and leads to a uniform distribution of residual stress.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Experimental and FEM Study of Residual Stresses During Ultra-Precision Turning of Aluminum 2024-T3

Aluminum 2024-T3 is commonly used in ultra-precision turning. In this study, the residual stresses of aluminum 2024-T3 were investigated by the finite element method (FEM) and a series of cutting experiments. The effects of depth of cut, cutting speed, rake angle and tool edge radius on the residual stresses were discussed by FEM. Moreover, an orthogonal simulation experiment was also conducted. The order of the strong-to-weak sequence of factors on residual stresses in cutting direction is the rake angle, tool edge radius, depth of cut and cutting speed. The cutting experiments were conducted and the surface residual stresses in the cutting direction were measured by X-ray diffraction. The experimental results showed that increasing cutting speed and decreasing tool edge radius can reduce the surface residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2016

TCR-contacting residues orientation and HLA-DRβ* binding preference determine long-lasting protective immunity against malaria

Fully-protective, long-lasting, immunological (FPLLI) memory against Plasmodium falciparum malaria regarding immune protection-inducing protein structures (IMPIPS) vaccinated into monkeys previously challenged and re-challenged 60 days later with a lethal Aotus monkey-adapted P. falciparum strain was found to be associated with preferential high binding capacity to HLA-DRβ1* allelic molecules of the major histocompatibility class II (MHC-II), rather than HLA-DRβ3*, β4*, β5* alleles. Complete PPII{sub L} 3D structure, a longer distance (26.5 Å ± 1.5 Å) between residues perfectly fitting into HLA-DRβ1*PBR pockets 1 and 9, a gauche{sup −} rotamer orientation in p8 TCR-contacting polar residue and a larger volume of polar p2 residues was also found. This data, in association with previously-described p3 and p7 apolar residues having gauche{sup +} orientation to form a perfect MHC-II-peptide-TCR complex, determines the stereo-electronic and topochemical characteristics associated with FPLLI immunological memory. - Highlights: • Stereo-electronic and topochemical rules associated with FPLLI immunological memory. • Presence of very high long-lasting antibody titres against Plasmodium falciparum Spz. • Protective memory induction associated with a binding capacity to HLA-DRβ1*. • gauche{sup −} rotamer orientation in p8 polar residue is related to is related to immunological memory.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Friction-stir-welding (FSW) has gained importance as an effective way to join dissimilar materials due to its solid-state nature. However, FSW produces substantial residual stresses in aluminum welding, often deteriorating the component's structural performance and reliability. In the current study, the d-spacing (inter-atomic distance) of several locations on a battery tray and stress-free reference samples are measured with neutron diffraction to calculate the residual stresses in a lap 6061 to A365 dissimilar friction-stir-weld. Furthermore, the present study connects the measured residual stress to microstructure properties through electron backscatter diffraction (EBSD) and optical microscopy analyses. The EBSD results indicate that the FSW operation affects the grains’ orientation, thereby producing location-specific directionally varying elasticity across the weldment. Further, this varied elasticity creates unique d-spacing profiles even in the stress-free material. Additionally, the resulting stressed and stress-free d-spacing profiles show dependencies on the FSW tool geometry, traverse direction, and rotational direction. Lastly, this study suggests that the final component residual stress can be influenced by the sequence of multi-pass welds contributing to a rise in temperature in the presence of a completed weld relaxing its residual stress.

36 MATERIALS SCIENCE↗