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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

From Well Log to Formation Model: A Novel Laboratory Calibrated Methodology with Demonstration

This work demonstrates how the characterization and modeling of both elastic and creep properties are essential to describe zones in layered rock formations as either low-stress targets for stimulation or high-stress barriers to fracture growth. Prediction of fracture height is critical for designing stimulation operations in oil and gas wells. Ideally, fractures are placed in target zones which will produce hydrocarbons and should not propagate into zones expected to be unproductive or to produce unwanted fluids such as water which in turn must be treated and/or disposed. The essential task in designing stimulation plans is predicting which zones have low horizontal stresses and which will be high-stress barriers to fracture growth. Despite this importance, there are gaps in current knowledge and a complete workflow from laboratory characterization to a finite element model which includes time dependent rock deformation is required. While the research and methodology presented here also have application to CO 2or hydrogen storage, wastewater injection, and geothermal applications, the focus will be on hydrocarbon extraction. This thesis presents the results of a characterization-to-prediction workflow for the Caney shale, which is an emerging hydrocarbon resource in Oklahoma, USA. It begins with an investigation to enable critical evaluation of the Caney zonation into nominally “brittle” and “ductile” zones based on properties observed from well logs. It shows none of the zones are consistently “brittle” or “ductile” mechanical behavior based on the variety of definitions of these terms. However, the nominally ductile zones are weaker and more prone to creep. A laboratory investigation of samples including strength, elastic, and creep properties, is then used in a finite element model of stress evolution. The model includes both elastic deformation and viscoplastic creep. Results predict the least creep-prone layers to have the lowest horizontal stresses, therefore comprising hydraulic fracturing targets. The most creep-prone layers attain a horizontal stress similar to the vertical stress and therefore are predicted to be high stress barriers to hydraulic fracture stimulation. In addition to defining stimulation target intervals, the model shows how as tectonic strain rate increases, there is a transition from creep-dominated stresses to stresses dominated by elasticity.

Benge, Margaret↗
NASA NTRS1994

Statistical scaling relationships and size effects in the strength and creep rupture of fibrous composites

In this presentation we discuss a new theoretical model and supporting experimental results for the strength and lifetime in creep rupture of unidirectional, carbon fiber/epoxy matrix composites at ambient conditions. First we review the 'standard' Weibull/power-law methodology that has been standard practice. Then we discuss features of a recent model which build on the statistical aspects of fiber strength, micromechanical aspects of stress transfer around fiber breaks, and time-dependent creep of the matrix. The model is applied to 'microcomposites' consisting of seven fibers in a matrix for which strength and creep-rupture data are available. The model yields Weibull distributions in an envelope format for both strength and lifetime. The respective shape, scale and power-law parameters depend on such parameters as the Weibull shape parameter for fiber strength, the exponent for matrix creep, the effective load transfer length (which grows in time due to matrix creep) and the critical cluster size for failed fibers. The experimental results are consistent with the theory, though time-dependent debonding appears to be part of the failure process.

Phoenix, S. Leigh↗
DOE OSTI2022

Cavitation-resistant intergranular precipitates enhance creep performance of θ'-strengthened Al-Cu based alloys

Tensile and compressive creep properties of a quaternary Al-Cu-Mn-Zr (ACMZ) alloy and its commercial counterpart (Al-Cu-Mn-Zr with Ni, Co and Sb additions, RR350) are investigated at 300°C. At low stresses up to 30 MPa where diffusional creep dominates, creep resistance is the same in tension and compression and RR350 deforms more slowly than ACMZ, consistent with RR350 alloy's larger linear fraction of intergranular precipitates (Al7Cu2(NiFe) and Al9FeNi for RR350 vs. θ-Al2Cu for ACMZ) and a reduced fraction of precipitate-free zones near grain boundaries. At stresses between 30 and 80 MPa, dislocation creep with a stress exponent n ~ 3 becomes rate-limiting in compression, which is expected to be controlled by θ' precipitates within the grain bulk. By contrast, in tension, enhanced creep rate and higher apparent stress exponents are measured, consistent with cavitation at intergranular precipitates becoming increasingly dominant as the stress increases. In the dislocation creep regime, RR350 alloy is again more creep resistant than ACMZ alloy, which is related to three mechanisms (i) a reduced fraction of softer precipitate-free zones, (ii) more effective load transfer to intergranular precipitates, and (iii) reduced cavitation. A model for cavitation is applied to calculate tensile creep rates from compressive creep rates and the model successfully predicts the improved tensile creep resistance of the RR350 alloy. Overall, the present investigation underscores the importance of intergranular grain boundary precipitates, in addition to strengthening θ' precipitates, in enhancing the creep resistance of Al-Cu alloys.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction↗
DOE OSTI2021

Initial Developments in Modeling Graphite Behavior

Graphite is used in High Temperature Reactor designs as a moderator, reflector and core material responsible for protecting the fuel and maintaining structural stability. From a safety perspective, it is imperative to be able to predict how graphite will behave under reactor operating conditions which may compromise the core’s structural integrity or fuel’s safety performance. The following report summarizes recent modeling work undertaken at Idaho National Laboratory which focuses on graphite degradation behavior. One phenomenon which is explored in this report and can cause significant degradation to graphite properties is oxidation. Oxidation behavior in graphite is highly temperature dependent. At low temperatures, oxygen can fully penetrate a component and cause a homogeneous damage profile. At high temperatures, only the graphite near the surface of a component is affected. Understanding and modeling this temperature dependence is essential to predicting graphite behavior. In this report, three graphite models are discussed. The first model is used to investigate strength loss after low temperature oxidation. It does this by generating an approximate graphite microstructure then determining the required load to cause crack propagation. It has been shown that the model reproduces the quasi brittle stress versus strain relationship observed in graphite. Strength loss results from the model are shown to match experimental values. The second model investigates strength loss under high temperature oxidation conditions. This model is more applicable to full scale graphite components where the oxidation damage is often inhomogeneous throughout a component. The third model computes stresses in graphite under reactor conditions. Specifically, the model incorporates the effect of creep, irradiation dose, thermal strains, and oxidation in order to predict internal stresses in a component. All of these models are implemented in the Multiphysics Object-Oriented Simulation Environment (MOOSE), an open source, parallel finite element framework.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Application of the Continuum Damage Mechanics Wilshire-Cano-Stewart (WCS) Model

In this study, the applications of the continuum damage mechanics-based Wilshire-Cano-Stewart (WCS) model are explored to predict rupture time, minimum-creep-strain-rate (MCSR), damage, damage evolution, and creep deformation. Increase knowledge in manufacturing methods has pushed the limit of material science and the development of new materials. Conventional testing is required to qualify materials against creep which according to the ASME B&PV III code, 10,000+ hours of experiments are necessary for each heat before materials are put into service. This process is costly and not feasible for new materials. As an alternative, models have been employed to predict creep behaviors and reduce the amount of time necessary for material qualification. Many models have been developed to predict distinct creep behaviors and the question of which model is best remains. Amongst current models, the WCS model has emerge with the ability to predict multiple behaviors using an explicit analytical approach with the ability to predict long-term creep. In this study the novel continuum damage mechanics WCS is employed in multiple applications. The goals of the study are (a) to discuss and determine the framework of the WCS model and validated it mathematically and using parametric simulations, (b) applied the model to accelerated creep data to show the capabilities of the model with non-conventional data, and (c) applied a novel numerical method, the datum temperature method (DTM) to show the model extrapolations and interpolations capabilities with limited and reduce data sets. To accomplish these goals, data is gathered for alloy P91 and Inconel 718 to develop and post-audit validate the model. The benefits of using the WCS model is that it provides an explicit stress and temperature dependency ideal for extrapolations, the coupled equations are suitable for finite element analysis (FEA) implementation, and it follows an explicit calibration approach. The model also proves that it can be applied to accelerated testing data and using the DTM.

Cano, Jaime A↗
DOE OSTI2024

Simulating the effect of grain structure and porosity on creep for powder bed fusion 316H

This report details results from modeling studies focused on identifying the potential factors influencing creep performance of 316H stainless steel manufactured using Laser Powder Bed Fusion (LPBF), with a focus on experimentally-observed and predicted differences between the response of the AM material and conventionally manufactured wrought 316H. The studies presented here systematically look at the role of grain structure, porosity and texture in the anisotropic creep behavior of the material under conditions expected in high temperature advanced nuclear reactors. A physics-based Crystal Plasticity Finite Element modeling approach has allowed us to look at these factors in isolation and study their role in the material's long-term deformation behavior. An update to the precipitation model used in the constitutive framework for 316H is also presented here, with the aim of improving the accuracy of our results from this modeling effort. This work is a step in the direction of gaining mechanistic understanding of the long-term deformation behavior of LPBF 316H, helping us model its long term performance and reducing the qualification time for the material.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Modelling of cracking during beam oscillation laser welding of a creep-resistant nickel alloy

During high power laser welding of Inconel 740H, horizontal solidification cracks form at locations between approximately 70–80% of the weld depth. With the integration of circular beam oscillation, the laser energy density distribution and underlying thermo-mechanical conditions were altered. By coupling three-dimensional heat transfer, fluid flow, and stress modelling tools, the role that circular beam oscillation plays in the formation of the strain rates and stresses driving this cracking phenomenon was identified. While the addition of a circular oscillation pattern appeared to lower the stress levels along the solidification front, it did not eliminate the appearance of horizontal cracking. Only when the beam amplitudes reached 1.6 mm did solidification cracking disappear, but the weld depths were also significantly reduced.

Gao, Mingze↗
DOE OSTI2025

CALPHAD-based ICME design of single-step aging to enhance mechanical strength of WAAM Haynes 282

To match the strength of wire-arc additive manufactured Haynes 282 to its wrought counterpart via a single-step aging heat treatment, the CALPHAD (Calculation of Phase Diagrams) method is integrated with physics-based process-structure-property models and experimental validation. The integrated computational materials engineering (ICME) framework simulates the effects of aging on γ′ and M 23 C 6 precipitation and the resulting yield strength. To improve simulation reliability, the interfacial energies between γ/γ′ and γ/M 23 C 6 carbides were estimated by comparison with precipitation kinetic modeling and measured precipitate sizes. γ′ and M23C6 were found to precipitate simultaneously between 640 and 860 °C, producing microstructures similar to those produced by two-step aging. The optimal γ′ size for peak yield stress was calculated to be 20–23 nm. WAAM Haynes 282 aged at 780 °C for 50 h exceeded the mechanical performance of its wrought counterpart subjected to two-step aging, though desired properties can also be achieved at 800 °C for 16 h or less. The error in yield strength is less than 20 MPa, demonstrating good agreement between the modeling framework and experiments. Creep studies showed that WAAM Haynes 282 exceeded the calculated rupture time, reaching 481 h. This proposed methodology can accelerate the design of aging heat treatments for any γ′-strengthened nickel-base alloy, minimizing the resources required for trial-and-error experiments.

CALPHAD↗
DOE OSTI2020

An Initial Assessment of the Design Margins of Different ASME Section III, Division 5 Design Rules

This report develops a method for assessing the design margin of the ASME Section III, Division 5 Class A design rules, focusing on a definition of margin as the ratio between the actual, expected component life and the ASME design life. Full inelastic finite element simulations with a complete damage model capturing the available creep, creep-fatigue, fatigue, and tension test failure data produce the expected component lives, which can then be compared to corresponding ASME design calculations. The focus of this particular work is on Alloy 617 and the ASME creep-fatigue design rules, but the approach is general and could be applied to other design limits and to other materials. A margin assessment of a representative Alloy 617 component shows the ASME creep-fatigue design rules applied to this component have a margin of 10 on design life. The report describes several challenges in completing a more comprehensive margin assessment of the ASME rules, in particular challenges in developing probabilistic assessment methods for high temperature structural components. The report details these challenge and discusses the immediate possibilities of the deterministic margin assessment method developed here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Reference constitutive model for Alloy 617 and 316H stainless steel for use with the ASME Division 5 design by inelastic analysis rules

This report describes the development, calibration, and validation of an inelastic constitutive model describing the monotonic, cyclic, and creep behavior of Alloy 617 from room temperature to 983 °C . The model is intended for incorporation into a new Nonmandatory Appendix to Section III, Division 5, Subsection HB, Subpart B of the ASME Boiler & Pressure Vessel Code providing guidance on developing models for use with the ASME design by inelastic analysis provisions as well as a listing of acceptable material models for each Class A material that designers can use without further validation. The report described the development of the A617 model as well as providing an updated draft appendix, ready for ASME ballot, incorporating the A617 and and the previously-developed 316H model. The development of this appendix and the related material models will promote the widespread application of the generally more efficient inelastic analysis rules rules.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Status memorandum on ORNL support of vendor irradiation capsule design and ASME irradiation code development and new ASTM test standard development activities

This report is in submission of completion of the Level 4 milestone number M4TG-24OR0501111 within the larger Advanced Reactor Technologies Gas Cooled Reactor program at Oak Ridge National Laboratory (ORNL). The focus of this year’s efforts is to continue support of industry needs related to the development of future industry-funded irradiation programs. At ORNL these efforts included the development of a generalized three-dimensional CAD model of an irradiation creep capsules for graphite, cost estimates of the expansion of the Materials Irradiation Facility (MIF), involvement with ASTM D02.F0 “Manufactured Carbon and Graphite Products” and the ASME Boiler and Pressure Vessel Code, and publication of papers supporting these efforts. This report will document the status of these activities.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1985

Constitutive modeling for single crystal superalloys

A crystallographic approach to constitutive modeling of single crystal superalloys is discussed. The approach is based on identifying the active slip planes and slip directions. The shear stresses are computed on each of the slip planes from applied stress components. The slip rate is then computed on each slip system and the microscopic inelastic strain rates are the sum of the slip in the individual slip systems. The constitutive model was implemented in a finite element code using twenty noted isoparametric solid elements. Constants were determined for octahedral and cube slip systems. These constants were then used to predict tension-compression asymmetry and fatigue loops. Other data was used to model the tensile and creep response.

Stouffer, Donald C.↗
NASA NTRS1992

Thermo-elastoviscoplastic snapthrough behavior of cylindrical panels

The thermo-elastoviscoplastic snapthrough behavior of simply supported cylindrical panels is investigated. The analysis is based on nonlinear kinematic relations and nonlinear rate-dependent unified constitutive equations which include both Bodner-Partom's and Walker's material models. A finite element approach is employed to predict the inelastic buckling behavior. Numerical examples are given to demonstrate the effects of several parameters which include the temperature, thickness and flatness of the panel. Comparisons of buckling responses between Bodner-Partom's model and Walker's model are given. The creep buckling behavior, as an example of time-dependent inelastic deformation, is also presented.

Song, Y.↗
NASA NTRS2006

Using ABAQUS Scripting Interface for Materials Evaluation and Life Prediction

An ABAQUS script has been written to aid in the evaluation of the mechanical behavior of viscoplastic materials. The purposes of the script are to: handle complex load histories; control load/displacement with alternate stopping criteria; predict failure and life; and verify constitutive models. Material models from the ABAQUS library may be used or the UMAT routine may specify mechanical behavior. User subroutines implemented include: UMAT for the constitutive model; UEXTERNALDB for file manipulation; DISP for boundary conditions; and URDFIL for results processing. Examples presented include load, strain and displacement control tests on a single element model. The tests are creep with a life limiting strain criterion, strain control with a stress limiting cycle and a complex interrupted cyclic relaxation test. The techniques implemented in this paper enable complex load conditions to be solved efficiently with ABAQUS.

Powers, Lynn M.↗
NASA NTRS2014

Tidal Modulation of Ice-shelf Flow: a Viscous Model of the Ross Ice Shelf

Three stations near the calving front of the Ross Ice Shelf, Antarctica, recorded GPS data through a full spring-neap tidal cycle in November 2005. The data revealed a diurnal horizontal motion that varied both along and transverse to the long-term average velocity direction, similar to tidal signals observed in other ice shelves and ice streams. Based on its periodicity, it was hypothesized that the signal represents a flow response of the Ross Ice Shelf to the diurnal tides of the Ross Sea. To assess the influence of the tide on the ice-shelf motion, two hypotheses were developed. The first addressed the direct response of the ice shelf to tidal forcing, such as forces due to sea-surface slopes or forces due to sub-ice-shelf currents. The second involved the indirect response of ice-shelf flow to the tidal signals observed in the ice streams that source the ice shelf. A finite-element model, based on viscous creep flow, was developed to test these hypotheses, but succeeded only in falsifying both hypotheses, i.e. showing that direct tidal effects produce too small a response, and indirect tidal effects produce a response that is not smooth in time. This nullification suggests that a combination of viscous and elastic deformation is required to explain the observations.

Tidal↗
NASA NTRS2016

Influence of Constituents on Creep Properties of SiC/SiC Composites

SiC-SiC composites are being considered as potential candidate materials for next generation turbine components such as combustor liners, nozzle vanes and blades because of their low density, high temperature capability, and tailorable mechanical properties. These composites are essentially fabricated by infiltrating matrix into a stacked array of fibers or fiber preform by one or a combination of manufacturing methods such as, Melt Infiltration (MI) of molten silicon metal, Chemical Vapor Infiltration (CVI), Polymer Infiltration and Pyrolysis (PIP). To understand the influence of constituents, the SiC-SiC composites fabricated by MI, CVI, and PIP methods were creep tested in air between 12000 and 14500 degrees Centigrade for up to 500 hours. The failed specimens were analyzed under a scanning electron microscope to assess damage mechanisms. Also, knowing the creep deformation parameters of the fiber and the matrix under the testing conditions, the creep behavior of the composites was modeled and compared with the measured data. The implications of the results on the long term durability of these composites will be discussed.

modeling↗
DOE OSTI2023

AGR-1, AGR-2, AGR-3/4, and AGR-5/6/7 DimensionalChange Analysis

A series of fuel irradiation experiments have been planned in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) to support the licensing and operation of the Advanced Reactor Technologies high temperature gas-cooled reactor. The advanced gas reactor (AGR) experiments are comprised of multiple independent capsules containing multiple cylindrical fuel compacts, placed inside of a graphite cylinder in ATR. The purpose of the AGR experiments is to provide data on fuel performance under irradiation, support fuel process development, qualify the fuel for normal operating conditions, provide irradiated fuel for accident testing, and support the development of fuel performance and fission product transport models. The advanced graphite creep (AGC) experiments provide irradiation creep data for design and licensing. To date, six irradiation campaigns have been completed: AGR-1 (December, 2006 – November, 2009); AGR-2 (June, 2010 – October, 2013); AGR-3/4 (December, 2011 – April, 2014); AGC-1 (September, 2009 – January, 2011); AGC-2 (April, 2011 – May, 2012); and AGC-3 (November, 2012 – April, 2014).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗