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Evaluation of three thermal stress relief treatments for 2219 aluminum alloy in terms of their effect on residual stress, mechanical properties, and stress corrosion resistance. The treatments are post aging and stress relieving fullscale and subscale parts formed in the aged T81 condition, and aging subscale parts formed in the unaged T31 condition.
This report presents an evolutionary cyclic plasticity based transformative approach for fatigue evaluation of safety critical components. This approach is generic which can be used not only for the present generation light water reactor components (which is our focus) but also for advanced reactor components. The approach is based on the fundamental concept of time-evolution of progressive fatigue damage rather than the end-of-life data based conventional S~N curve approaches. Series of fatigue tests on 316 stainless steel uniaxial specimens were conducted under strain-controlled and stress-controlled cyclic loading in two different environment such as in-air at 300 °C and PWR coolant water condition at 300 °C. Material models are developed to capture the uniaxial test data and are subsequently programmed into commercially available ABAQUS code to transform the uniaxial material behavior to multiaxial loading domain. The developed evolutionary cyclic-plasticity approach is verified by both analytical and 3D-FE modeling of uniaxial fatigue test specimens. Results show that the developed material models can capture the time-dependence of material hardening and softening with great accuracy. In addition, results show that the material models not only can capture the material behavior under constant amplitude loading but also can capture the load-sequence effect under variable and random amplitude loading. The ANL developed approach is one of its kind, which shows first in the fatigue research community that fatigue evaluation of a component (in our case verified for laboratory scale fatigue test specimens with great accuracy) can be performed for its entire fatigue life, including the hardening and softening behavior, without using a conventional S~N curve based approach. Additionally results are presented related to fatigue evaluation of real reactor components such as of a pressurized water reactor (PWR) surge line (SL), under upset transient conditions. SLs of PWR experience complex thermal stratification due to the mixing of differential temperature flow from hot leg and pressurizer. A detailed parametric study of thermal stratification in SL is performed through both standalone computational fluid dynamics (CFD) analysis and fluid-structure-interaction based coupled CFD and heat transfer analysis. Results show that the mass flow rate in SL substantially affects the extent of its thermal stratification. The resulting thermal boundaries conditioned are used as inputs for thermal-mechanical stress analysis and component level fatigue evaluation. Fatigue evaluation of SL pipe under example loading conditions was performed using the above-mentioned evolutionary-plasticity based approach and ASME code (for in-air life) and NUREG-6909 (for PWR environment life) based approaches. Results show that the evolutionary plasticity based approach estimate substantially different life compared to the conventional ASME based approach. To show the entirety of the proposed evolutionary fatigue-modeling framework, this report includes the results presented in semi-annual March report (ANL/LWRS-17/01). Sections 2-5 of March report are directly included as Sections 2-5 in this report, without any significant changes. However, Sections 6-9 of this report present the work performed during March-September of 2017. Whereas, Sections 1 and 10 present the organization of this report and the summary and future work, respectively. This report (ANL/LWRS-17/03 Rev. 1) is a slightly revised version of the earlier published report (ANL/LWRS-17/03). In this revised version, some of the results and associated discussion have been corrected/updated.
Thermoelastic or thermal stress is a potentially important contributor to the state of stress in the oceanic lithosphere. The present paper provides several simple models for the state of thermoelastic stress in a young oceanic lithosphere, taking into account a comparison of the predictions of these models with the characteristics of near-ridge earthquakes. Attention is given to the characteristics of near-ridge earthquakes, sources of stress in an oceanic lithosphere, previous models of thermal stress, the calculation of thermal stress, and thermal stress models. A test is conducted of the hypothesis that thermoelastic stress is a significant component of the stress field in a young oceanic lithosphere. The considered models support the hypothesis that thermoelastic stress is a significant component of the stress field in a young oceanic lithosphere.
The plasma sprayed graded layered yittria stabilized zirconia (ZrO2)/metal(CoCrAlY) seal system for gas turbine blade tip applications up to 1589 K (2400 F) seal temperatures was studied. Abradability, erosion, and thermal fatigue characteristics of the graded layered system were evaluated by rig tests. Satisfactory abradability and erosion resistance was demonstrated. Encouraging thermal fatigue tolerance was shown. Initial properties for the plasma sprayed materials in the graded, layered seal system was obtained, and thermal stress analyses were performed. Sprayed residual stresses were determined. Thermal stability of the sprayed layer materials was evaluated at estimated maximum operating temperatures in each layer. Anisotropic behavior in the layer thickness direction was demonstrated by all layers. Residual stresses and thermal stability effects were not included in the analyses. Analytical results correlated reasonably well with results of the thermal fatigue tests. Analytical application of the seal system to a typical gas turbine engine application predicted performance similar to rig specimen thermal fatigue performance. A model for predicting crack propagation in the sprayed ZrO2/CoCrAlY seal system was proposed, and recommendations for improving thermal fatigue resistance were made. Seal system layer thicknesses were analytically optimized to minimize thermal stresses in the abradability specimen during thermal fatigue testing. Rig tests on the optimized seal configuration demonstrated some improvement in thermal fatigue characteristics.
Integrated elemental, spectroscopic (infrared spectroscopy and X-ray absorption near-edge structure), and gas intrusion (helium pycnometry and nitrogen adsorption) analyses are used to characterize the bulk chemical, molecular, and physical microstructures of kerogen spanning a thermal maturity transect (vitrinite reflectance, Ro, from 0.5% to 2.6%) across the Woodford Shale of the Anadarko Basin, Oklahoma. The integration takes advantage of novel procedures to prepare kerogen isolates that preserve both the chemical and physical properties of the organic matter in the bulk shale. The Woodford kerogens follow the expected trends in H/C and O/C coordinates during thermal maturation for type II kerogen. Infrared spectra show that loss of hydrogen from kerogen is related to cracking of hydrogen-rich aliphatic (alkyl) carbon structures from aromatic carbons. Within the range of Ro values < 1.5%, peripheral aromatic carbons remain highly substituted with alkyl (methyl and methylene) and probably heteroatom functional groups. At Ro values > 1.5%, these substitutions are substantially removed and replaced by hydrogen. The evolution of carbon structures inferred from the IR spectra is supported by known carbon bond dissociation energies for carbonaceous materials. Total organic sulfur and sulfur-XANES data show that sulfur in Woodford kerogens is dominated by aromatic sulfur (thiophene) and that reactive, aliphatic sulfur (sulfide) is eliminated at low degrees of thermal stress (Ro ≤ 0.9%). At higher thermal stress, sulfur speciation is stable and dominated by thermally stable thiophene. The physical properties of Woodford kerogens evolve during thermal maturation in a manner consistent with their molecular characteristics. Skeletal density of kerogen increases during maturation in a manner that is linearly correlated to its atomic H/C ratio and inferred aromatic carbon content. The specific surface area of kerogen also increases during maturation, reflecting the development of internal pores within the kerogen skeletal framework as aliphatic carbon structures are preferentially cracked and expelled from solid kerogen. The quantitative chemical and structural changes expressed by the Woodford kerogens during thermal maturation, including their hydrogen and carbon content, carbon speciation, and skeletal density, are shown by comparison to not be measurably different for other type II kerogens from numerous oil- and gas-producing shale plays, indicating that thermal stress acts to drive maturation of type II kerogen in a similar way globally.
Results are presented for a finite-element investigation of the combined influence of edge effects due to mechanical and thermal mismatch in composite laminates with free edges. Laminates of unidirectional boron/epoxy symmetrically bonded to sheets of aluminum and titanium were studied. It is shown that interlaminar thermal stresses may be more significant than the interlaminar stresses due to loading only. In addition, the stresses due to thermal mismatch may be of the same sign as those due to Poisson's mismatch or they may be of opposite sign depending upon material properties, stacking sequence, and direction of loading. The paper concludes with a brief discussion of thermal stresses in all-composite laminates.
The relationship between crustal tectonics and thermal evolution is discussed in terms of the moon and Mercury. Finite strain theory and depth and temperature-dependent thermal expansion are used to evaluate previous conclusions about early lunar history. Factors bringing about core differentiation in the first 0.6 b.y. of Mercurian evolution are described. The influence of concentrating radioactive heat sources located in Mercury's crust on the predicted contraction is outlined. The predicted planetary volume change is explored with regard to quantitative limits on the extent of Mercurian core solidification. Lunar and Mercurian thermal stresses involved in thermal evolution are reviewed, noting the history of surface volcanism. It is concluded that surface faulting and volcanism are closely associated with the thermal evolution of the whole planetary volume. As the planet cools or is heated, several types of tectonic and volcanic effects may be produced by thermal stress occurring in the lithosphere.
The present paper describes the development of a new hybrid computational approach for applicability for nonlinear/linear thermal structural analysis. The proposed transfinite element approach is a hybrid scheme as it combines the modeling versatility of contemporary finite elements in conjunction with transform methods and the classical Bubnov-Galerkin schemes. Applicability of the proposed formulations for nonlinear analysis is also developed. Several test cases are presented to include nonlinear/linear unified thermal-stress and thermal-stress wave propagations. Comparative results validate the fundamental capablities of the proposed hybrid transfinite element methodology.
In this research, thermal residual stresses were incorporated in an analysis of fiber-bridged matrix cracks in unidirectional and cross-ply titanium matrix composites (TMC) containing center holes or center notches. Two TMC were investigated, namely, SCS-6/Timelal-21S laminates. Experimentally, matrix crack initiation and growth were monitored during tension-tension fatigue tests conducted at room temperature and at an elevated temperature of 200 C. Analytically, thermal residual stresses were included in a fiber bridging (FB) model. The local R-ratio and stress-intensity factor in the matrix due to thermal and mechanical loadings were calculated and used to evaluate the matrix crack growth behavior in the two materials studied. The frictional shear stress term, tau, assumed in this model was used as a curve-fitting parameter to matrix crack growth data. The scatter band in the values of tau used to fit the matrix crack growth data was significantly reduced when thermal residual stresses were included in the fiber bridging analysis. For a given material system, lay-up and temperature, a single value of tau was sufficient to analyze the crack growth data. It was revealed in this study that thermal residual stresses are an important factor overlooked in the original FB models.
Because SiCSiC ceramic matrix composites (CMCs) are under consideration for use as turbine engine hot-section components in extreme environments, it becomes necessary to investigate their performance and damage morphologies under complex loading and environmental conditions. Monitoring of electrical resistance (ER) has been shown as an effective tool for detecting damage accumulation of woven melt-infiltrated SiCSiC CMCs. However, ER change under complicated thermo-mechanical loading is not well understood. In this study a systematic approach is taken to determine the capabilities of ER as a relevant non-destructive evaluation technique for high heat-flux testing, including thermal gradients and localized stress concentrations. Room temperature and high temperature, laser-based tensile tests were conducted in which stress-dependent damage locations were determined using modal acoustic emission (AE) monitoring and compared to full-field strain mapping using digital image correlation (DIC). This information is then compared with the results of in-situ ER monitoring, post-test ER inspection and fractography in order to correlate ER response to convoluted loading conditions and damage evolution.
Here, we report calculated elastic tensors, axial Grüneisen parameters, and thermal stress distributions in Al 2 Mo 3 O 12 , ZrMgMo 3 O 12 , Sc 2 Mo 3 O 12 , and Y 2 Mo 3 O 12 , a series of isomorphic materials for which the coefficients of thermal expansion range from low-positive to negative. Thermal stress in polycrystalline materials arises from interactions between thermal expansion and mechanical properties, and both can be highly anisotropic. Thermal expansion anisotropy was found to be correlated with elastic anisotropy: axes with negative thermal expansion were less compliant. Calculations of axial Grüneisen parameters revealed that the thermal expansion anisotropy in these materials is in part due to the Poisson effect. Models of thermal stress due to thermal expansion anisotropy in polycrystals following cooling showed thermal stresses of sufficient magnitude to cause microcracking in all cases. The thermal expansion anisotropy was found to couple to elastic anisotropy, decreasing the bulk coefficient of thermal expansion and leading to lognormal extremes of the thermal stress distributions.
When exposed to combustion environments containing moisture both un-reinforced and fiber reinforced silicon based ceramic materials tend to undergo surface recession. To avoid surface recession environmental barrier coating systems are required. However, due to differences in the elastic and thermal properties of the substrate and the environmental barrier coating, thermal residual stresses can be generated in the coated substrate. Depending on their magnitude and nature thermal residual stresses can have significant influence on the strength and fracture behavior of coated substrates. To determine the maximum residual stresses developed during deposition of the coatings, a finite element model (FEM) was developed. Using this model, the thermal residual stresses were predicted in silicon nitride substrates coated with three environmental coating systems namely barium strontium aluminum silicate (BSAS), rare earth mono silicate (REMS) and earth mono di-silicate (REDS). A parametric study was also conducted to determine the influence of coating layer thickness and material parameters on thermal residual stress. Results indicate that z-direction stresses in all three systems are small and negligible, but maximum in-plane stresses can be significant depending on the composition of the constituent layer and the distance from the substrate. The BSAS and REDS systems show much lower thermal residual stresses than REMS system. Parametric analysis indicates that in each system, the thermal residual stresses can be decreased with decreasing the modulus and thickness of the coating.
The design temperature of high plutonium concentration ZPPR fuel assemblies is 600 degrees C. Cladding integrity of the 304L stainless steel cladding is a significant concern with this fuel since even small holes can lead to substantial fuel degradation. Since the fuel has a higher coefficient of thermal expansion than the cladding, an investigation of the stress induced in the cladding due to the differential thermal expansion of fuel and cladding up to the design temperature was conducted. Small holes in the cladding envelope would be expected to lead to the fuel hydriding and oxidizing into a powder over a long period of time. This is the same type of chemical reaction chain that exists in the degradion of the high uranium concentration ZPPR fuel. Unfortunately, the uranium fuel was designed with vents which allowed this degradation to occur. The Pu cladding is sealed so only fuel with damaged cladding would be subject to this damage. The thermal stresses that can be developed in the fuel cladding have been calculated in in this paper and compared to the ultimate tensile stress of the cladding. The conclusion is drawn that thermal stresses cannot induce holes in the cladding even for the highest storage temperatures predicted in calculations (292°C). In fact, thermal stress can not cause cladding failure as long as the fuel temperatures are below the design limit of 600 degrees C (1,112 degrees F).
The thermally induced stresses and deformations in layered, orthotropic tubes are studied. The motivation for studying tubes is their likely application for use in space structures. Tubes are a strong candidate for this application because of their high structural efficiency, as measured by stiffness per unit weight, and their relative ease of fabrication. Also, tubes have no free edges to deteriorate or delaminate. An anticipated thermal condition for tubes in space is a circumferential temperature gradient. This type of gradient will introduce dimensional changes into the structure and may cause stresses large enough to cause damage to the material. There are potentially large differences in temperatures at different circumferential locations on the tube. Because of this, the effects of temperature dependent material properties on the stresses and deformations may be important. The study is composed of three parts: experiments to determine the functional form of the circumferential gradient and to measure tube deflections; an elasticity solution to compute the stresses and deformations; and an approximate approach to determine the effects of temperature dependent material properties.
The problem of obtaining the minimum-mass design of mechanically and thermally loaded structures is presented. The special nature of thermal stresses with regard to their response to resizing of structural members is discussed. It is shown that conventional resizing procedures which are based on driving the total stress to its allowable value may be inefficient when the thermal stress in an element makes up a significant fraction of the total stress. An improved algorithm for resizing of structures subjected to thermal stresses is treated. In this algorithm the mechanical portions of the stresses were driven to their maximum allowable values. The thermal stresses were used to adjust the allowable values of the mechanical stresses. The new algorithm was exercised for a number of truss structures of varying complexity and compared with ordinary fully stressed design.
A matrix of structural concepts suitable for Mach 5 hydrogen-fueled hypersonic vehicles are defined, and a thermostructural analysis of each is presented. The thermal environment encountered in this flight regime mandates hot structures of superalloy materials or insulated structures using more conventional materials such as titanium, aluminum, and composites. This paper compares the thermostructural performance of several concepts. The various structures are initially sized to carry a 2.5 g subsonic maneuver load. The structural weights are determined, and these components are then evaluated in a transient heating program along with various thermal protection systems to determine the minimum weight combination. The temperature profiles generated for these minimum weight solutions are used as input to a structural analysis along with a model of the appropriate structural concept to calculate thermal stresses. Generally, hot structure concepts have higher thermal stresses. In most cases, the thermal stresses are below the yield strength of the material. It is shown that integral tanks have weights similar to nonintegral tank concepts for the same level of technology. Moreover, an insulated tubular aluminum-composite structure with nonintegral tanks appear attractive for near-term vehicles.
The general theory of conduction in a piezoresistive material subjected to temperature change is derived and the basic equations needed to design and apply test chips for thermal stress measurement are established. A general expression is obtained for the resistance changes which occur in an arbitrarily oriented 1D filamentary conductor subjected to general 3D stress states and arbitrary temperature changes. The derived formula is valid for crystals such as silicon which have cubic symmetry and diamond lattice structures. Basic equations are presented for the resistance changes experienced by stressed in-plane resistors fabricated on (100) silicon wafers. The established theory is applied to a simple two-element sensor rosette. A test chip containing this rosette configuration is designed and fabricated, and a suitable calibration system is constructed.
In this paper, we present thermal-mechanical stress analysis of a pressurized water reactor pressure vessel and its hot-leg and cold-leg nozzles. Results are presented from thermal and thermal-mechanical stress analysis under reactor heat-up, cool-down, and grid load-following conditions. Analysis results are given with and without the presence of preexisting crack in the reactor nozzle (axial crack in hot leg nozzle). From the model results it is found that the stress-strain states are significantly higher in case of presence of crack than without crack. In conclusion, the stress-strain state under grid load following condition are more realistic compared to the stress-strain state estimated assuming simplified transients.