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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

High frequency content in nonlinear soil response: A numerical artifact or a reality?

This article probes the reasons for the presence of high frequency components, which are not a part of the input, in the output of nonlinear site response analysis. The nonlinear site response analysis of a single soil element, under a single frequency sinusoidal displacement, is conducted to demonstrate the presence of frequencies higher than the input frequency in the soil element's shear stress and the free surface acceleration. The parameters of this one element problem are chosen carefully to minimize numerical errors. The shape of the stress-strain hysteresis loop is found to be the main cause for the presence of these higher frequencies. A quasi-static problem similar to the direct shear test is then considered to analyze the effect of different hysteresis shapes. Through this analysis, it is numerically and analytically shown that any deviation of the stress-strain hysteresis shape from a perfect ellipse results in output frequencies higher than the input frequency and the number of higher frequencies produced depends on whether the hysteresis shape is smooth or pointed.

42 ENGINEERING↗
DOE OSTI2025

Enhanced Interfacial Bonding of Graft Copolymers

To understand how thermoplastic welding strength can be tuned through chemical modifications and macromolecular topology, we combined coarse-grained molecular dynamics (MD) simulations with experimental validation. Our simulations examined the diffusion dynamics of both linear and graft polymers across representative interfaces, revealing that diffusion-controlled interdigitation follows a power law, with the exponent decreasing from 0.34 to 0.11 as grafting density increases from 7.5 to 196% (with side chains grafted to both sides of a monomer unit). The addition of side chains enhances welding efficiency, as dense bottlebrush polymers with high grafting density reach maximum rupture strength faster than linear polymers. However, their saturated rupture strength is lower. This observation is subsequently corroborated by experimental lap-shear tests comparing linear polyethylene with octene grafted polyethylene elastomers. Our MD simulations show that unlike linear polymers, where backbone entanglements dominate, the grafted side chains introduce mechanisms in addition to entanglement dilution. The rapid interdigitation of side chains creates a dense mesh of entropic van der Waals contacts, which can also enhance the film welding. Furthermore, our MD simulations reveal a brittle rupture behavior in linear and comb-like (mildly grafted) polymers, while bottlebrush (densely grafted) polymers display elastomeric behavior with a pronounced stress plateau prior to fracture. Our simulations deconvolute the influence of polymer topology on deformation behavior. The rate of polymer deformation becomes lower than the applied strain rate prior to rupture, and the onset of this deviation is progressively delayed from linear to bottlebrush polymers. This trend highlights the critical role of molecular architecture in governing the mechanical response. In conclusion, these results provide deeper insight into the underlying welding mechanisms of topological polymers and present a potential approach for mitigating the interface anisotropy that is inherent in advanced manufacturing techniques such as fused filament fabrication.

graft copolymers↗
DOE OSTI2026

Brittle-to-Ductile Transition Temperature Decreases at the Microscale in Muscovite Mica

Characterizing the structural and chemical transitions of muscovite mica across various scales and thermal profiles is essential for ensuring the reliability of high-voltage power insulation, aerospace thermal barriers, and nanoscale semiconductor substrates under extreme operational stress. Here, we investigate notch fracture toughness $K^{n}_{Ic}$ of muscovite mica as a function of feature size w and temperature T with microscale shear testing. $K^{n}_{Ic}$ decreased and then stayed constant as w increased, likely from fabrication-induced changes to the microstructure and roughness. Moreover, $K^{n}_{Ic}$ initially decreased and then increased as temperature T increased, with the reversal in trend indicative of a brittle-to-ductile transition. Complementary Raman spectroscopy and molecular dynamics showed that the observed trends were due to an increase in bond lengths and a decrease in critical stresses/strains. In comparing the microscale results to macroscale counterparts, it was surmised that the decrease in brittle-to-ductile transition temperature was due to an increase in the dehydroxylation rate.

DelRio, Frank W. [Sandia National Laboratories (SN↗
DOE OSTI2020

Rapid Mineral Precipitation During Shear Fracturing of Carbonate-Rich Shales

Target subsurface reservoirs for emerging low-carbon energy technologies and geologic carbon sequestration typically have low permeability and thus rely heavily on fluid transport through natural and induced fracture networks. Sustainable development of these systems requires deeper understanding of how geochemically mediated deformation impacts fracture microstructure and permeability evolution, particularly with respect to geochemical reactions between pore fluids and the host rock. Here, a series of triaxial direct shear experiments was designed to evaluate how fractures generated at subsurface conditions respond to penetration of reactive fluids with a focus on the role of mineral precipitation. Calcite-rich shale cores were directly sheared under 3.5 MPa confining pressure using BaCl 2 -rich solutions as a working fluid. Experiments were conducted within an X-ray computed tomography (xCT) scanner to capture 4-D evolution of fracture geometry and precipitate growth. Three shear tests evidenced nonuniform precipitation of barium carbonates (BaCO 3 ) along through-going fractures, where the extent of precipitation increased with increasing calcite content. Precipitates were strongly localized within fracture networks due to mineral, geochemical, and structural heterogeneities and generally concentrated in smaller apertures where rock:water ratios were highest. The combination of elevated fluid saturation and reactive surface area created in freshly activated fractures drove near-immediate mineral precipitation that led to an 80% permeability reduction and significant flow obstruction in the most reactive core. While most previous studies have focused on mixing-induced precipitation, this work demonstrates that fluid–rock interactions can trigger precipitation-induced permeability alterations that can initiate or mitigate risks associated with subsurface energy systems.

58 GEOSCIENCES↗
DOE OSTI2017

Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel

Friction stir scribe technology, a derivative of friction stir welding, was applied for the dissimilar lap welding of an aluminum alloy and galvanized mild steel sheets. During the process, the rotating tool with a cobalt steel scribe first penetrated the top material — aluminum — and then the scribe cut the bottom material — steel. The steel was displaced into the upper material to produce a characteristic hook feature. Lap welds were shear tested, and their fracture paths were studied. Welding parameters affected the welding features including hook height, which turned out to be highly related to fracture position. Therefore, in this paper, the relationships among welding parameters, hook height, joint strength and fracture position are presented. In addition, influence of zinc coating on joint strength was also studied. Keywords: friction stir scribe technology; dissimilar material welding; zinc coating; hook height; joint strength; fracture position

Aluminum↗
DOE OSTI2024

Optimization of Structurally Enhanced Solder Transient Liquid Phase Bonding

High temperature packaging technologies are a necessity for high temperature capable devices. SAC305 solder has an operational limit of 174°C imposed by creep effects which aligns well with current junction temperature limits of 175°C. Wide band gap semiconductor materials have the potential to reach junction temperatures of up to 800°C that are not currently attainable with significant reliability. Capitalizing on this potential will requires substrates and attachments that can operate well beyond the current 175°C standard. Silver sintering pastes have received widespread interest as a high temperature attachment alternative. However, the process requires high pressure bonding in an inert environment to achieve acceptable bond quality. Transient liquid phase (TLP) sintering is capable of good bond quality without pressure requirements but suffers from low thermal conductivity and only slightly reduced cost compared to silver sintering. SAC305 solder contains the same constituent materials for TLP as available copper-tin TLP sintering paste. By introducing engineered surface structures into the bond, intermetallic formation can be accelerated producing a bond similar to TLP sintering but in an ambient environment and for reduced cost. While this process has been demonstrated, it has not yet been optimized. Currently bonds are formed using a 75 μm stencil on substrate surface structures 24 μm tall, covering 19% of the bonding area. The process takes about 4 hours not including the formation of surface structures. Here, this study will center on the effects of stencil thickness and coating methods. Samples will be analyzed by scanning acoustic microscopy, die shear testing and cross sectional scanning acoustic microscopy.

42 ENGINEERING↗
DOE OSTI2021

Stationary Shoulder Friction Stir Assisted Scribe Technique for Dissimilar Joining

We report on implementation of a stationary shoulder in dissimilar joints of Al-steel and Al-carbon fiber reinforced polymer (CFRP) using friction stir assisted scribe technology (FaST ). Viable joint strength similar to that with the conventional FAST process was demonstrated in Al-steel. A significant improvement in as-welded surface roughness for both Al-steel and Al-CFRP cases was achieved by using stationary shoulder. Interrupted lap shear tests performed on Al-steel joints and a corresponding computational model indicate the joint failure typically occurs in Al sheet via a crack tip that originates at the steel hook tip on the loading side. A similar fracture path was observed in an Al-CFRP joint.

Das, Hrishikesh↗
DOE OSTI2019

Prediction of the Shear Failure of Opened Rock Fractures and Implications for Rock Slope Stability Evaluation

Rock slope commonly fails due to the shear failure of rock fractures. Shear strength of rock fractures are reduced substantially once the fracture surfaces are mismatched or opened. We propose a new criterion to predict the shear strength of rock fractures in different opening states. The degree of interlocking representing the true asperity contact area is incorporated into the modified model of Saeb and Amadei. The effect of fracture opening on asperity dilation and degradation is separately considered. The transitional stress that is a critical parameter involved in the model is analytically determined based on energy consideration. The new model is validated with experimental results from direct shear tests on synthetic fractures with regular‐shaped asperities. Good agreement between the analytical solution and the experimental data confirms the capacity of the proposed model. Therefore, the model has great potential for assessing the stability of rock slopes where fractures are often opened due to stress relief and engineering disturbances.

Li, Yingchun (ORCID:0000000201083704)↗
DOE OSTI2022

Fused Filament Fabrication of Polycarbonate in a Reactive Atmosphere

Fused Filament Fabrication (FFF) has become extremely useful in various industries, particularly when complex parts are needed in low volumes. However, the material properties available in FFF polymers are limited in scope. The properties of a FFF part can be changed in multiple ways. This study explores changing the bulk properties of a part by affecting each layer as it prints. Prior work has demonstrated the feasibility of altering polymer properties by layerwise exposure to a liquid chemical, but properties have never been modified in situ using a reactive gas. Here, FFF is done in the presence of a reactive gas. Specifically, the part is printed with polycarbonate in a reactive atmosphere of ozone and ultra-violet light. It was found that as each layer is exposed to a reactive gas, the bulk properties of the part change. A visual chemical change was seen, as well as confirmation of the reaction through Fourier transform infrared spectroscopy attenuated total reflectance. The change in mechanical properties was measured through Dynamic Mechanical Analysis shear tests, showing a bulk change can be efficiently produced through FFF in a reactive atmosphere.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 3: Major component development

Analytical and experimental investigations, performed to establish the feasibility of reinforcing metal aircraft structures with advanced filamentary composites, are reported. Aluminum-boron-epoxy and titanium-boron-epoxy were used in the design and manufacture of three major structural components. The components were representative of subsonic aircraft fuselage and window belt panels and supersonic aircraft compression panels. Both unidirectional and multidirectional reinforcement concepts were employed. Blade penetration, axial compression, and inplane shear tests were conducted. Composite reinforced structural components designed to realistic airframe structural criteria demonstrated the potential for significant weight savings while maintaining strength, stability, and damage containment properties of all metal components designed to meet the same criteria.

Bryson, L. L.↗
NASA NTRS1974

Polyimide resin composites via in situ polymerization of monomeric reactants

Thermo-oxidatively stable polyimide/graphite-fiber composites were prepared using a unique in situ polymerization of monomeric reactants directly on reinforcing fibers. This was accomplished by using an aromatic diamine and two ester-acids in a methyl alcohol solvent, rather than a previously synthesized prepolymer varnish, as with other A-type polyimides. A die molding procedure was developed and a composite property characterization conducted with high modulus graphite fiber tow. Flexure, tensile, compressive, and shear tests were conducted at temperatures from 72 to 650 F on laminates before and after exposures at the given temperatures in an air environment for times up to 1000 hours. The composite material was determined to be oxidatively, thermally, and hydrolytically stable.

Cavano, P. J.↗
NASA NTRS1975

Solid state welding processes for an oxide dispersion strengthened nickel-chromium-aluminum alloy

Solid-state welding processes were evaluated for joining TD-NiCrAl (Ni-16Cr-4Al-2ThO2) alloy sheet. Both hot-press and resistance spot welding techniques were successfully applied in terms of achieving grain growth across the bond line. Less success was achieved with a resistance seam welding process. In stress-rupture shear and tensile shear tests of lap joints at 1100 C, most failures occurred in the parent material, which indicates that the weld quality was good and that the welds were not a plane of weakness. The overall weld quality was not as good as previously attained with TD-NiCr, probably because the presence of alumina at the faying surfaces and the developmental TD-NiCrAl sheet, which was not of the quality of the TD-NiCr sheet in terms of surface flatness and dimensional control.

Moore, T. J.↗
NASA NTRS1975

Studies of finite element analysis of composite material structures

Research in the area of finite element analysis is summarized. Topics discussed include finite element analysis of a picture frame shear test, BANSAP (a bandwidth reduction program for SAP IV), FEMESH (a finite element mesh generation program based on isoparametric zones), and finite element analysis of a composite bolted joint specimens.

Douglas, D. O.↗