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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Trends in Field and Laboratory Performance of Photovoltaic Modules and Materials

This DuraMAT project intends to identify bill of materials (BOM) and/or process control measures for photovoltaic modules with representative failure modes as informed by accelerated and field tests to guide next steps in module and material design. We have begun work to identify correlation between module field performance and accelerated testing results by cross-comparing a module database of accelerated test results with a module database of fielded systems. We have identified fielded systems with degraded performance, and intend to compare this to the results observed in certification and qualification testing. We also intend to apply lessons and observations from accelerated tests to the field, where it may be possible to mitigate or avoid degradation in the field.

DuraMAT↗
DOE OSTI2023

A diffusion–deformation model with damage for polymer undergoing rapid decompression failure

Green hydrogen is emerging as one of the most promising alternatives to replace fossil fuels. While hydrogen gas has a good energy density by weight, its poor energy density by volume requires it to be stored under high pressure for commercial use. The hydrogen infrastructure developed to handle this high pressure hydrogen contains multiple components made of polymers as sealing agents. Although polymers do not react chemically with hydrogen gas, they undergo a mechanical failure when high pressure hydrogen gas is suddenly depressurized. This phenomenon known as 'rapid decompression failure' occurs due to the diffusion of hydrogen through polymer and getting trapped inside pre-existing cavities or voids. Here, in this paper, a continuum mechanics-based coupled diffusion-deformation-damage model was developed to predict the hydrogen distribution, stress distribution, and damage propagation inside the polymer while it undergoes rapid decompression failure. The polymer was modeled as a hyperelastic material because it represents the nonlinear material response observed in uniaxial tensile tests perfectly. The effects of hydrogen diffusivity, pre-existing cavity size, cavity location, applied hydrogen pressure, and depressurization rate on damage initiation were studied. It was found that the coefficient of diffusion plays an important role in damage initiation and damage was mostly concentrated in the inside areas rather than near the surface. Experiments were conducted with EPDM polymer which agreed well with the predicted trends using the given model. The effect of adding carbon black and silica filler particles and plasticizer to the pure EPDM polymer was also studied. It was found that damage during RDF decreases with the addition of fillers, but increases with the addition of the plasticizer. Finally, the damage evolution in the presence of two cavities was also studied, and was found that the interaction of stress fields around the cavities alters the damage occurring during RDF.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Physics-based model of irradiation creep for ferritic materials under fusion energy operation conditions

Irradiation creep is known to be an important process for structural materials in nuclear environments, potentially leading to creep failure at temperatures where thermal creep is generally negligible. While there is a great deal of data for irradiation creep in steels and zirconium alloys in light water reactor conditions, much less is known for first wall materials under fusion energy conditions. Lacking suitable fusion neutron sources for detailed experimentation, modeling, and simulation can help bridge the dose-rate and spectral-effects gap and produce quantifiable expectations for creep deformation of first wall materials under standard fusion conditions. In this paper, we develop a comprehensive model for irradiation creep created from merging a crystal plasticity representation of the dislocation microstructure and a defect evolution simulator that accounts for the entire cluster dimensionality space. Both approaches are linked by way of a climb velocity that captures dislocation-biased defect absorption and a dislocation strengthening term that reflects the accumulation of defect clusters in the system. Here, we carry out our study in Fe under first wall fusion reactor conditions, characterized by a fusion neutron spectrum with average recoil energies of 20 keV and a damage dose rate of ≈3×10 –7 dpa/s at temperatures between 300 and 800 K.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Irradiation creep model for α-Fe: Dislocation climb in the presence of stress fields (Final Report)

Irradiation creep is known to be an important process for structural materials in nuclear environments, potentially leading to creep failure at temperatures where thermal creep is generally negligible. While there is a great deal of data for irradiation creep in steels and zirconium alloys in light water reactor conditions, much less is known for first wall materials under fusion energy conditions. Lacking suitable fusion neutron sources for detailed experimentation, modeling, and simulation can help bridge the dose-rate and spectral-effects gap and produce quantifiable expectations for creep deformation of first wall materials under standard fusion conditions. In this work, we present a comprehensive model for irradiation creep created from merging a crystal plasticity representation of the dislocation microstructure and a defect evolution simulator that accounts for the entire cluster dimensionality space. Both approaches are linked by way of a climb velocity that captures dislocation-biased defect absorption and a dislocation strengthening term that reflects the accumulation of defect clusters in the system. We carry out our study in Fe under first wall fusion reactor conditions, characterized by a fusion neutron spectrum at temperatures between 300 and 800°K.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Effects of fabric architectures on mechanical and damage behaviors in carbon/epoxy woven composites under multiaxial stress states

The mechanical properties and damage evolutions of carbon/epoxy woven fabric composites with three different fabric architectures, including one plain weave and two twill weave patterns, are experimentally investigated under multiaxial stress states. In particular, the effects of weave patterns are investigated by monotonic and cyclic off-axis tension tests. Both elastic modulus and strength degrade remarkably with increasing off-axis loading angle, while Poisson's ratio is much higher than that measured from on-axis tests and increases with loading strain gradually. Different fabric architectures show limited effects on the modulus and strength under multiaxial stress states, and they are well predicted by transformation equation and Tsai-Wu failure criteria, respectively. However, significantly different failure behaviors are observed in three fabric composites, and microstructure observation shows that fabric architecture affects the stress concentration and the damage development. Smaller crimp ratio and compacted structure postpone the damage development but result in more abrupt failure under multiaxial stress states.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Chloride-Induced Stress Corrosion Cracking of Friction Stir-Welded 304L Stainless Steel: Effect of Microstructure and Temperature

Dry storage canisters of used nuclear fuels are fabricated using SUS 304L stainless steel. Chloride-induced stress corrosion cracking (CISCC) is one of the major failure modes of dry storage canisters. The cracked canisters can be repaired by friction stir welding (FSW), a low-heat input ‘solid-phase’ welding process. It is important to evaluate the ClSCC resistance of the friction stir welded material. Stress corrosion cracking (SCC) studies were carried out on mill-annealed base materials and friction stir welded 304L stainless U-bend specimens in 3.5% NaCl + 5 N H2SO4 solution at room temperature and boiling MgCl2 solution at 155 °C. The engineering stress on the outer fiber of the FSW U-bend specimen was ~60% higher than that of the base metal (BM). In spite of the higher stress level of the FSW, both materials (FSW and BM) showed almost similar SCC failure times in the two different test solutions. The SCC occurred in the thermo-mechanically affected zone (TMAZ) of the FSW specimens in the 3.5% NaCl + 5 N H2SO4 solution at room temperature, while the stirred zone (SZ) was relatively crack-free. The failure occurred at the stirred zone when tested in the boiling MgCl2 solution. Hydrogen reduction was the cathodic reaction in the boiling MgCl2 solution, which promoted hydrogen-assisted cracking of the heavily deformed stirred zone. The emergence of the slip step followed by passive film rupture and dissolution of the slip step could be the SCC events in the 3.5% NaCl + 5 N H2SO4 solution at room temperature. However, the slip step height was not sufficient to cause passivity breakdown in the fine-grained SZ. Therefore, the SCC occurred in the partially recrystallized softer TMAZ. Overall, the friction-stirred 304L showed higher tolerance to ClSCC than the 304L base metal.

304L austenitic stainless steel↗
DOE OSTI2021

An exploration of benchtop X–ray emission spectroscopy for precise characterization of the sulfur redox state in cementitious materials

The evolution of sulfur chemistry in cements is best known in the bailiwick of failure mechanisms via sulfate attack but is equally important for its contributions to the reduction capacity of cementitious materials often used for immobilizing nuclear waste streams destined for long-term storage, e.g., cementitious waste forms (CWF). The total reduction capacity of CWFs, encompassing contributions from both S and Fe reductants, and its implications toward radionuclide immobilization is most often studied by destructive wet chemistry methods requiring acid digestion in the presence of Ce(IV) and subsequent titration and colorimetric interpretation. Here, we investigate a similarly analytical but nondestructive alternative, benchtop high resolution wavelength-dispersive x-ray fluorescence spectroscopy, most commonly known as x-ray emission spectroscopy (XES), for probing the bulk sulfur oxidation state distribution. We present here an initial investigation of S XES, including an improved experimental protocol for lab XES of inhomogeneous samples, both as a complement to the Ce(IV) test and for new scientific opportunities that it enables for observing changes in sulfur chemistry. We discuss future improvements and opportunities, including: (1) the practical challenges associated with coordinating XES and Ce(IV) liquid extraction for a more comprehensive perspective on reduction capacity and for a high-precision evaluation of uncertainties in the Ce(IV) test; and (2) new opportunities, due to the nondestructive nature of XES, for controlled evolution studies aimed at elucidating specific chemical responses of CWF’s exposed to invasive gas or liquid species or to accelerated aging by radiative dose or thermal treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Simulation of hardened cement degradation and estimation of uncertainty in predicted failure times with peridynamics

Modeling the degradation of cement-based infrastructure due to aqueous environmental conditions continues to be a challenge. In order to develop a capability to predict concrete infrastructure failure due to chemical degradation, here we created a chemomechanical model of the effects of long-term water exposure on cement paste. The model couples the mechanical static equilibrium balance with reactive–diffusive transport and incorporates fracture and failure via peridynamics (a meshless simulation method). The model includes fundamental aspects of degradation of ordinary Portland cement (OPC) paste, including the observed softening, reduced toughness, and shrinkage of the cement paste, and increased reactivity and transport with water induced degradation. This version of the model focuses on the first stage of cement paste decalcification, the dissolution of portlandite. Given unknowns in the cement paste degradation process and the cost of uncertainty quantification (UQ), we adopt a minimally complex model in two dimensions (2D) in order to perform sensitivity analysis and UQ. We calibrate the model to existing experimental data using simulations of common tests such as flexure, compression and diffusion. Then we calculate the global sensitivity and uncertainty of predicted failure times based on variation of eleven unique and fundamental material properties. We observed particularly strong sensitivities to the diffusion coefficient, the reaction rate, and the shrinkage with degradation. Also, the predicted time of first fracture is highly correlated with the time to total failure in compression, which implies fracture can indicate impending degradation induced failure; however, the distributions of the two events overlap so the lead time may be minimal. Extension of the model to include the multiple reactions that describe complete degradation, viscous relaxation, post-peak load mechanisms, and to three dimensions to explore the interactions of complex fracture patterns evoked by more realistic geometry is straightforward and ongoing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Design of a 2 MW ZrC/W-based molten-salt-to-sCO 2 PCHE for concentrated solar power

To increase the power cycle efficiency and lower the levelized cost of electricity (LCOE) of concentrated solar power (CSP) plants, printed circuit heat exchangers (PCHEs) capable of operating above 700 °C with molten chloride salt and a sCO 2 -based fluid are needed. In this paper, the design of a high-pressure, high-temperature, 2 MW PCHE comprised of a thermomechanically-robust, zirconium carbide/tungsten (ZrC/W) composite is conducted for CSP plants. The ZrC/W composite is a material with high thermal conductivity, high stiffness, and high failure strength at high temperatures, along with excellent resistance to thermal cycling and thermal shock. In this work, a thermomechanical design analysis was conducted to select appropriate material thicknesses of the ZrC/W plates, and to determine the geometrical dimensions and the thermal performance of the PCHE. The influences of the plate number and heat exchanger length on power density and pressure drop have also been systematically investigated. Economic analyses were conducted to compare the cost of ZrC/W-based PCHEs to those comprised of IN740H (a state-of-the-art, nickel-based superalloy) and 316 stainless steel (316SS). Finally, at a sufficiently high plate production rate, the manufacturing cost of ZrC/W-based PCHEs can be significantly lower, while achieving a much higher power density, compared with state-of-the-art, nickel alloy-based and stainless steel-based PCHEs.

14 SOLAR ENERGY↗
DOE OSTI2023

Strength distributions of laminated FeNi-based metal amorphous nanocomposite ribbons

Metal Amorphous Nanocomposite (MANC) materials offer low losses at high magnetic switching frequency, enabling high power density motors with increased rotational speed. While MANCs have high strength, they are brittle. The use of motor components such as a rotor consisting of brittle material presents a reliability concern. Here, a promising MANC alloy is subjected to tensile tests and failure is observed with high-speed photography. A method is developed to prepare tensile specimens of laminated MANC and epoxy layers, simulating the stacking of an epoxy-impregnated tape-wound core. Tensile tests are conducted for single layer ribbon and for five- and ten-layer stacks of laminated material with thin layers of thermosetting epoxy. Failure distributions are shown to have increasing Weibull modulus with increasing layer count. The composite MANC material system is modeled using chain-of-bundles models. Using a k-failure model, we show that single ribbon strength distribution data can be used to predict well the failure distribution of laminated stacks. The agreement occurs when the assumed ineffective length, over which load is recovered in a failed layer, is comparable to the observed interlaminar separation length.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Probabilistic Failure Criterion of SiC/SiC Composites Under Multiaxial Loading

Owing to its excellent mechanical properties and stability under high temperature and neutron irradiation conditions, SiC/SiC composites have emerged as a promising material for light water reactors (LWRs) in the development of accident-tolerant fuel (ATF) systems. Structural integrity and retention of hermeticity are two crucial requirements for SiC/SiC claddings during normal operations, and both of them are closely related to the proportional limit stress (PLS) of the material. Understanding the behavior of SiC/SiC composites under multiaxial stress states and developing a probabilistic approach for evaluating the structural vulnerability are of paramount importance for reliability-based analysis and design of SiC/SiC composite claddings. So far, there has been very limited effort towards experimental and analytical investigations of probabilistic failure of SiC/SiC claddings. This critical knowledge gap motivates this research. A probabilistic failure criterion for SiC/SiC composites under multi-axial loading is developed, and this criterion is incorporated into reliability analysis of the structural integrity of SiC/SiC fuel cladding. The research consists of two parts: 1) experimental investigation of multiaxial failure behavior of SiC/SiC composites, and 2) theoretical modeling of time-dependent probabilistic failure of SiC/SiC cladding. In the experimental investigation, the PLS is determined through the examination of stress-strain response, the acoustic emission measurement, as well as the X-ray computed tomography. The theoretical framework is derived by combin- ing the finite weakest-link statistical model and the subcritical damage growth model. This theoretical model captures the time-dependent failure mechanism of the material, which has a major consequence for predicting the lifetime distribution of the cladding. Meanwhile, the model also predicts that the failure statistics of the cladding depends strongly on the cladding length. The results of the multiaxial experiments reveal the level of statistical variation of the PLS of SiC/SiC materials under different stress states. The theoretical model provides a robust analytical tool for extrapolation of small-scale laboratory test results to the behavior of full-scale claddings. These findings establish a scientific foundation for the development of reliability-based design of SiC/SiC fuel claddings, which will play an essential role in improving the structural safety and integrity of LWRs.

42 ENGINEERING↗
DOE OSTI2025

Fabrication and Evaluation of Large Alumina Crucibles by Vat Photopolymerization Additive Manufacturing for High-Temperature Actinide Chemistry

Additive manufacturing (AM) offers opportunities to advance the design and function of ceramic tooling in high temperature actinide pyrochemistry. In technical ceramics such as alumina, conventional forming techniques often restrict design flexibility and can limit experimental progress. In this study, we investigate the use of vat photopolymerization (VP) with commercial resins to fabricate large-scale alumina crucibles, reaching dimensions up to 125 mm, which is significantly larger than typically reported for dense VP ceramics. Notably, these additively manufactured components are produced using consumer-grade hardware, which limits process control, but offers significant upside in scalability and accessibility. Using microscopy and X-ray computed tomography, the VP alumina parts have high bulk densities above 95%, but also the prevalence of AM-induced artifacts and surface defects. Mechanical testing showed these defects to significantly reduce flexural strength and compromise part reliability. Electrorefining trials under sustained exposure to molten salts and metals reveal mixed results, with the AM material exhibiting high chemical compatibility, but mechanical failures due to the reduced strength were prevalent. Our findings illustrate both the promise and current limitations of AM ceramics for actinide chemistry, and point toward future improvements in process optimization, design strategies, and part screening to enhance performance and reliability.

Materials science↗
DOE OSTI2021

Prediction of Aluminum to Steel RSW Joint Failure (CRADA 405)

General Motors, LLC has developed a resistance spot welding process to join aluminum sheet to steel for body-in-white manufacturing. Efforts to develop the process for any one joint configuration (combination of alloy and thicknesses) is intensive. To aid in process understanding and eventual reduction in process development efforts, an initiative was created to develop an finite element model of the various destructive test configurations (lap shear, cross-tension, and coach peel) to help predict the failure mode and load displacement curves under tensile testing. This report describes the finite element modeling approach, the means by which local material properties were determined, as well as model validation and refinement efforts.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Why Firn Quakes

Snow dampens sounds, but anecdotal reports concisely describe audible propagating collapse events—firnquakes—in Antarctic and Arctic snowfields. We propose combining granular and continuum mechanics to form a testable theory for conditioning, triggering, and propagation of firnquakes consistent with scarce data. A central condition for collapse events is unconsolidated firn at depth. As firn grains compact, stresses are transmitted along force chains which carry the overburden and transition into a continuous medium by pressure sintering. This granular legacy creates solid-like supports of denser layers that keep the material below unconsolidated. Dynamic amplification triggers local brittle failure of the supports, which induces a cascade of collapse propagation. Using bulk density from ice cores as proxy for stiffness, we find the flexural wave speed by collapsing supports matches the recorded firnquake velocities on the order of 100 m/s. Our theory is to be tested in firn sheets and other compacting granular materials.

Voigtländer, A. [Lawrence Berkeley National Labora↗
DOE OSTI2021

A Multiscale Modeling Approach to Cryocompressed Hydrogen Storage Pressure Vessels – Part II: Constitutive Modeling and Finite Element Analysis

Subjected to thermomechanical cycling, composite cryogenic hydrogen (H2) storage pressure vessels experience high stresses in the carbon fiber (CF)/epoxy overwrap which can lead to vessel failure due to a combination of degradation mechanisms such as matrix cracking, fiber/matrix debonding, delamination, and fiber rupture. The present paper is the second part of a set of two articles on this subject that addresses analysis and design of these pressure vessels. Predictive finite element (FE) modeling capabilities have been used to support a material acceptance process that aims at providing guidance to evaluate specialty resins, vessel liner options, and CF composites through thermomechanical testing. We have applied a multiscale modeling approach recently developed (B.N. Nguyen et al., International Journal of Hydrogen Energy, 2019, https://doi.org/10.1016/j.ijhydene.2019.09.200) to perform three-dimensional (3D) FE analysis and design of a cryo-compressed H2 storage pressure vessel for its operation in a large temperature range from room to cryogenic temperatures. The developed approach termed the micro-meso-macro approach determines the laminar stresses in different layers of the vessel in addition to constituent (i.e., fiber and matrix) stresses that are important to the design of the composite overwrap for its layup and material combination to reduce the risk of vessel failure.

Nguyen, Ba Nghiep↗
DOE OSTI2025

Extrusion‐Spheronization of Mock Energetic Materials

The primary method for producing plastic bonded explosive (PBX) granules, or “prills”, has remained relatively unchanged for 70 years despite the complex nature of the process. In this work, we demonstrate the feasibility of using an extrusion‐spheronization technique to produce prills for PBX applications. We begin by detailing an inert formulation with similar properties of PBXs and then demonstrate the extrusion‐spheronization processing of these materials. A study is then performed where the spheronization process time of the extruded materials is varied and the resultant prills are morphologically characterized. Further, these prills are then pressed into high‐density articles and subject to compression testing to elucidate trends in process, properties, and performance. It was found that, for our formulation (95 wt.% melamine/5 wt.% polymer binder) and process, a spheronization time of 60 s yielded relatively uniform particles that exhibited improved poured, tapped, and pressed densities. Mechanical strength did not have a strong trend with process time as all spheronized materials had similar peak compression stress at failure. After further optimization, extrusion‐spheronization may be a promising path for future PBX formulation.

extrusion spheronization↗
DOE OSTI2020

Influence of temperature on accessible pyrolysis pathways of homopolymerized bisphenol A/F epoxies and copolymers

Understanding the thermal pyrolysis of epoxies and their copolymers is important for identifying structural changes resultant from thermal transients, enabling identification of failure modes of high-performance composite materials. This work expands our understanding of the thermal pyrolysis of cured epoxies and the role of temperature and composition on products, pathways, and relative rates. Numerous researchers have explored the pyrolysis of bisphenol A (BPA) epoxy. Significantly fewer have studied bisphenol F (BPF), and copolymers of BPA and BPF have been neglected. In this work, a pyrolysis gas chromatography mass spectrometer (PY-GC-MS) was used to investigate the degradation mechanism of homopolymerized BPA, BPF epoxies and their copolymers. Additionally, for polymer identification, pyrolysis >450 °C resulted in the most extensive fragmentation and is useful for material identification, though lower temperatures show different degradation product profiles that provide mechanistic insight into thermal degradation pathways. Temperature greatly influences the accessible pyrolysis pathways of BPA, revealing dual mechanisms of formation for products p-isopropylphenol and p-isopropenylphenol. For BPF at low pyrolysis temperature the p,p-bisphenol F isomer is produced at significantly lower relative abundance compared to the abundance at higher temperatures tested, but production of the other two isomers changes little with respect to temperature. This suggests the epoxy components consisting of the p,p-bisphenol F isomer have higher thermal stability. Overall, the copolymer epoxies were found to have similar degradation products in stoichiometric distributions. The major exception was the formation of the p,p-bisphenol F isomer, which shows evidence of thermal stabilizing effects from addition of BPA epoxy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Failure Analysis of Solder Joints

Soldering is a critical filler material joining process found in nearly all modern electronics. Ensuring solder joint reliability is crucial for the safety, performance, and cost-effectiveness of microelectronics.

42 ENGINEERING↗