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DOE OSTI2025

Multiplexing Focusing Analyzer for Efficient Stress-Strain Measurements

Statement of the problem or situation that is being addressed. Although thermal and cold neutron scattering is widely used and is critical for success in many areas of materials science and engineering, relatively low neutron fluxes severely limit applications of not only laboratory neutrons generators, but also large national neutron facilities. State-of-the-art thermal and cold neutron sources are large expensive national facilities, which serve diverse community of scientific and industrial users. The constant need to improve the instruments performance, stems from the fact that neutron methods are gaining in popularity, and becoming more and more powerful, while new neutron sources are not being constructed to keep pace with the developments and needs of the scientific community. Small research reactors at universities and National Labs, and laboratory-based neutron generators, are necessary not only for education and training, but also when samples cannot be transported to other facilities. However, the standard neutron techniques, which were developed for high-flux facilities, require much higher efficiencies to be used effectively with the low fluxes of small sources. Thus, the efficient use of neutron sources, such as with our proposed analyzer, is important for the progress and broader use of these neutron techniques. General statement of how this problem is being addressed. We propose to design and demonstrate novel diffractive optical device, which will enable very efficient residual stress neutron diffractometers. The proposed device will be a multi-foil analyzer, where each foil is constructed of focusing bent single crystals of Si. Such device will enable polychromatic residual stress neutron diffraction. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast measurements for determining residual stress tensors, raster large samples or screen multiple samples. Commercial Applications and Other Benefits The outcome of this project would be the demonstration of commercial devices, novel neutron optical components, which could be utilized to improve the performance of existing instruments or build novel neutron scattering instruments at DOE neutron facilities and commercial laboratory neutron sources. These new devices will widen the scope of research conducted using neutrons and enable measurements not feasible at present. Summary for Members of Congress Thermal and cold neutron beams are a powerful materials science probe, which provide unique information about the structure of matter. The proposed innovations expand the reach of neutron-based investigations to new materials and industries by enabling new instrumentation capabilities, thereby greatly enhancing and expanding the role of small, laboratory-based neutron instrumentation, and improving education and training of neutron users.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1974

Small-scale yielding analysis of mixed mode plane-strain crack problems

The small-scale yielding analysis of an elastic-plastic body with a line crack under plane-strain conditions subject to combinations of Mode I and II loadings is examined. The analysis of the near-tip field follows the works of Hutchinson and Rice and Rosengren. Dominant singularity solutions governing the asymptotic behavior of the stresses and strains at the crack tip are obtained for the complete range of loadings between Mode I and II. The results of an accurate finite element technique, which imbeds the dominant singularity solutions, directly relates the near-tip behavior to the elastic stress intensity factors K(I) and K(II). Implications of this study to mixed mode fracture mechanics is also discussed, particularly with respect to the direction of crack initiation and the relation of fracture toughness under mixed modes to that in Mode I. Details of the mixed mode plastic zone sizes and shapes are also given.

Shih, C. F.↗

DOE OSTI2020

Size effect in stainless steel thin wires under tension

Miniaturization of modern devices drives the exploration into how materials behave in small dimensions. However, the mechanical behaviors of micro-scale specimens under varied loading conditions are still challenging to characterize and predict. In this work, specimen size-dependent weakening effect was experimentally revealed in 316L stainless steel thin wires under tension with wire diameter decreasing from 200 μm down to 61 μm. The underlying mechanisms were primarily associated with surface grain softening and strain localization, which were largely dependent on the number of grains across wire diameter. Through an analog composite model with surface and interior grains that follows the Hall-Petch relation, the extent of surface grain softening was found to coincide with the flow stress reduction due to lack of boundary strengthening. Further using elasto-plastic self-consistent polycrystal modeling, the stress-strain behaviors of interior and surface grains were well described in analogy to those of bulk materials with similar-size grains and extremely large grains, respectively. Subsequently, the analog composite model well simulated the specimen size-dependent weakening effect under tension. This article provided more insights into the size effect exploration and proposed a practical model for describing size-dependent mechanical behaviors of small-scale materials to be applied to miniaturized devices.

316L stainless steel↗

DOE OSTI2023

Robust deep learning framework for constitutive relations modeling

Modeling the full-range deformation behaviors of materials under complex loading and materials conditions is a significant challenge for constitutive relations (CRs) modeling. Here, we propose a general encoder-decoder deep learning framework that can model high-dimensional stress-strain data and complex loading histories with robustness and universal capability. The framework employs an encoder to project high-dimensional input information (e.g., loading history, loading conditions, and materials information) to a lower-dimensional hidden space and a decoder to map the hidden representation to the stress of interest. We evaluated various encoder architectures, including gated recurrent unit (GRU), GRU with attention, temporal convolutional network (TCN), and the Transformer encoder, on two complex stress-strain datasets that were designed to include a wide range of complex loading histories and loading conditions. All architectures achieved excellent test results with an root-mean-square error (RMSE) below 1 MPa. Additionally, we analyzed the capability of the different architectures to make predictions on out-of-domain applications, with an uncertainty estimation based on deep ensembles. The proposed approach provides a robust alternative to empirical/semi-empirical models for CRs modeling, offering the potential for more accurate and efficient materials design and optimization.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Predicted Fracture Tendency of Naturally Occurring Aluminum Surface Coatings under Tensile Loading

Naturally occurring coatings on aluminum metal, such as its oxide or hydroxide, serve to protect the material from corrosion. Understanding the conditions under which these coatings mechanically fail is therefore expected to be an important aspect of predictive models for aluminum component lifetimes. To this end, we develop and apply a molecular dynamics (MD) modeling framework for conducting tension tests that is capable of isolating factors governing the mechanical strength as a function of coating chemistry, defect morphology, and variables associated with the loading path. We consider two representative materials, including γ-Al 2 O 3 and γ-Al(OH) 3 (i.e., oxide and hydroxide), both of which form readily as aluminum surface coatings. Our results indicate that defects have a significant bearing on the strength of aluminum oxide, with grain boundaries serving to reduce the strain at failure from ε zz = 0.300 to 0.219, relative to perfect single crystal. Our simulations also predict that porosity lowers the elastic stiffness and yield strength of the oxide. Relative to perfect crystal, we find porosity factors of 5%, 10% and 20% decrease the yield stress by 26%, 36% and 53%, respectively. MD predicts that perfect hydroxide and oxide single crystal have respective strains at failure of 0.08 and 0.31 under tensile uniaxial strain loading, and that the corresponding yield stresses are respectively 1.6 and 11.1 GPa. These data indicate that the hydroxide is substantially more susceptible to mechanical failure than the oxide. Our results, coupled with literature findings that indicate hot and humid conditions favor formation of hydroxide and defective oxide coatings, indicate the potential for a complicated dependence of aluminum corrosion susceptibility and stress corrosion cracking on aging history.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Search for subgrid scale parameterization by projection pursuit regression

The dependence of subgrid-scale stresses on variables of the resolved field is studied using direct numerical simulations of isotropic turbulence, homogeneous shear flow, and channel flow. The projection pursuit algorithm, a promising new regression tool for high-dimensional data, is used to systematically search through a large collection of resolved variables, such as components of the strain rate, vorticity, velocity gradients at neighboring grid points, etc. For the case of isotropic turbulence, the search algorithm recovers the linear dependence on the rate of strain (which is necessary to transfer energy to subgrid scales) but is unable to determine any other more complex relationship. For shear flows, however, new systematic relations beyond eddy viscosity are found. For the homogeneous shear flow, the results suggest that products of the mean rotation rate tensor with both the fluctuating strain rate and fluctuating rotation rate tensors are important quantities in parameterizing the subgrid-scale stresses. A model incorporating these terms is proposed. When evaluated with direct numerical simulation data, this model significantly increases the correlation between the modeled and exact stresses, as compared with the Smagorinsky model. In the case of channel flow, the stresses are found to correlate with products of the fluctuating strain and rotation rate tensors. The mean rates of rotation or strain do not appear to be important in this case, and the model determined for homogeneous shear flow does not perform well when tested with channel flow data. Many questions remain about the physical mechanisms underlying these findings, about possible Reynolds number dependence, and, given the low level of correlations, about their impact on modeling. Nevertheless, demonstration of the existence of causal relations between sgs stresses and large-scale characteristics of turbulent shear flows, in addition to those necessary for energy transfer, provides important insight into the relation between scales in turbulent flows.

Meneveau, C.↗

DOE OSTI2020

10° off-axis testing of CFRP using DIC: A study on strength, strain and modulus

For the determination of the shear properties such as strength, strain and modulus of unidirectionally reinforced composites, nearly a dozen measurement techniques exist, several of which have found their way into standards. One non-standardized method for sheet materials is the 10° off-axis tensile test of unidirectional coupons. The current work focuses on the experimental investigation of tensile testing of CFRP-UD coupon specimens using the 10° off-axis test and DIC strain mapping to measure the full-field deformation response. A sensitivity analysis on the measured stresses, strains and moduli is performed by varying the aspect ratio of the specimens and the location of strain measurement. Test related uncertainties such as the loading angle and specimen preparation details are investigated and quantified with the help of these full-field DIC measurements.

42 ENGINEERING↗

NASA NTRS1976

Application of strainrange partitioning to the prediction of MPC creep-fatigue data for 2 1/4 Cr-1 Mo steel

Creep-fatigue tests were conducted on annealed 2.25Cr-1Mo steel in air at 538 C involving interspersion of rapid strain cycles (0 to 22 cycles) between constant tensile stress-hold periods (23 or 47 hours). Life predictions were made on the basis of the strain range-life relations obtained from short-time material characterization tests on tubular specimens taken from the same heat as the specimens for the creep-fatigue tests. The creep-fatigue tests lasted from about 500 to 5000 hours, while the short-time tests used as the prediction basis lasted from 0.1 to 100 hours. By partitioning the creep and plastic strains within every cycle and summing the damage on a cycle-by-cycle basis, the predicted lives agreed with the observed ones within factors of two.

Saltsman, J. F.↗

NASA NTRS1984

Toughening mechanism in elastomer-modified epoxy resins, part 2

The role of matrix ductility on the toughenability and toughening mechanism of elastomer-modified DGEBRA epoxies was investigated. Matrix ductility was varied by using epoxide resins of varying epoxide monomer molecular weights. These epoxide resins were cured using 4,4' diaminodiphenyl sulfone (DDS) and, in some cases, modified with 10% HYCAR(r)CTBN 1300X8. Fracture roughness values for the neat epoxies were found to be almost independent on the monomer molecular weight of the epoxide resin used. However, it was found that the fracture toughness of the elastomer-modified epoxies was very dependent upon the epoxide monomer molecular weight. Tensile dilatometry indicated that the toughening mechanism, when present, is similar to the mechanisms found for the piperidine cured epoxies in Part 1. SEM and OM corroborate this finding. Dynamic mechanical studies were conducted to shed light on the toughenability of the epoxies. The time-dependent small strain behavior of these epoxies were separated into their bulk and shear components. The bulk component is related to brittle fracture, whereas the shear component is related to yielding. It can be shown that the rates of shear and bulk strain energy buildup for a given stress are uniquely determined by the values of Poisson's ratio, nu. It was found that nu increases as the monomer molecular weight of the epoxide resin used increases. This increase in nu can be associated with the low temperature beta relaxation. The effect of increasing cross-link density is to shift the beta relaxation to higher temperatures and to decrease the magnitude of the beta relaxation. Thus, increasing cross-link density decreases nu and increases the tendency towards brittle fracture.

Yee, A. F.↗

NASA NTRS1989

Review Of Fiber-Optic Electric-Field Sensors

Tutorial paper reviews state of art in fiber-optic sensors of alternating electric fields. Because such sensors are made entirely of dielectric materials, they are relatively transparent to incident electric fields; they do not distort fields significantly. Paper presents equations that express relationships among stress, strain, and electric field in piezoactive plastic and equations for phase shift in terms of photoelastic coefficients and strains in optical fiber.

De Paula, Ramon P.↗

NASA NTRS1990

Airframe structural optimization for maximum fatigue life

A methodology is outlined for optimization of airframe structures under dynamic constraints to maximize service life of specified fatigue-critical components. For practical airframe structures, this methodology describes the development of sensitivity analysis and computational procedures for constraints on the steady-state dynamic response displacements and stresses. Strain energy consideration is used for selection of structural members for modification. Development of a design model and its relation to an analysis model, as well as ways to reduce the dimensionality of the problem via approximation concepts, are described. This methodology is demonstrated using an elastic stick model for the MH-53J helicopter to show service life improvements of the hinge fold region.

D. P. Schrage↗

NASA NTRS1988

Geodetic Measurement of Deformation East of the San Andreas Fault in Central California

Triangulation and trilateration data from two geodetic networks located between the western edge of the Great Valley and the San Andreas fault have been used to calculate shear strain rates in the Diablo Range and to estimate the slip rate along the Calaveras and Paicines faults in Central California. Within the Diablo Range the average shear strain rate was determined for the time period between 1962 and 1982 to be 0.15 + or - 0.08 microrad/yr, with the orientation of the most compressive strain at N 16 deg E + or - 14 deg. The orientation of the principal compressive strain predicted from the azimuth of the major structures in the region is N 25 deg E. It is inferred that the measured strain is due to compression across the folds of this area: the average shear straining corresponds to a relative shortening rate of 4.5 + or - 2.4 mm/yr. From an examination of wellbore breakout orientations and the azimuths of P-axes from earthquake focal mechanisms the inferred orientation of maximum compressive stress was found to be similar to the direction of maximum compressive strain implied by the trend of local fold structures. Results do not support the hypothesis of uniform fault-normal compression within the Coast Ranges. From trilateration measurements made between 1972 and 1987 on lines that are within 10 km of the San Andreas fault, a slip rate of 10 to 12 mm/yr was calculated for the Calaveras-Paicines fault south of Hollister. The slip rate of the Paicines fault decreases to 4 mm/yr near Bitter.

Sauber, Jeanne M.↗

NASA NTRS1983

The dynamic tensile strength of ice and ice-silicate mixtures

The dynamic tensile strength of icy media is measured at strain rates on the order of 10,000/sec to aid in the understanding of impact and cratering phenomena. Compressed samples consisting of ice and ice-silicate mixtures with 5 and 30 wt % sand were impacted at temperatures between 230 and 250 K by projectile plexiglas plates imparting the required strain rates in less than 0.75 microsec. Taking the tensile stress corresponding to the transition from intact to spalled or fragmented samples as the dynamic tensile strength, strengths of 17, 20 and 22 MPa were obtained for the pure ice, 5 wt % sand, and 30 wt % sand specimens, respectively. The values lie considerably above those observed in static testing. A continuum fracturing model is used to obtain relations between tensile strength and stress rate as well as to derive stress and damage histories during tensile loading and the size distribution of icy fragments as a function of strain rate.

Lange, M. A.↗

DOE OSTI2023

A selection approach using high‑oxygen and pond-mimicking culture conditions increases biomass productivity in the industrially relevant diatom Nitzschia inconspicua str. hildebrandi

To meet the energy and food challenges of the 21st century, renewable and sustainable sources of fuel and nutrients are required. Microalgae offer promise in meeting these challenges but must achieve higher rates of areal productivity to compete with fully scaled, existing industries. In this study, we used selective O 2 pressure to attain a ~90% increase in areal biomass productivity relative to the parental strain in the diatom Nitzschia inconspicua str. hildebrandi under pond-mimicking conditions with high O 2 stress. The resulting strain (GAI-337) was tested further for dilution time, culture density, CO 2 supplementation, pH, temperature, and dissolved O 2 concentration under outdoor pond-mimicking conditions to improve areal productivities. These experiments yielded an optimum harvest and dilution time just after sunset, ~0.45 g AFDW L -1 initial culture density for maximal productivities, no requirement for CO 2 gas supplementation or pH control, maximal performance under a diel temperature curve going from 24 °C at night to 36 °C during the day, and benefits from some O 2 removal from the culture by bubbling with air. Using pond-mimicking laboratory bioreactors, N. inconspicua GAI-337 achieved ~42 g AFDW m -2 d -1 , placing it among the most productive microalgal strains tested to date. Nutrient limitation experiments resulted in a biomass composition with 36% of AFDW comprised of lipids (measured as FAMEs) that equated to ~160 Gallons of Gasoline Equivalent energy per ton AFDW, highlighting the potential of GAI337 as a promising renewable fuel feedstock strain.

09 BIOMASS FUELS↗

DOE OSTI2023

Combining synchrotron X-ray diffraction, mechanistic modeling and machine learning for in situ subsurface temperature quantification during laser melting

Laser melting, such as that encountered during additive manufacturing, produces extreme gradients of temperature in both space and time, which in turn influence microstructural development in the material. Qualification and model validation of the process itself and the resulting material necessitate the ability to characterize these temperature fields. However, well established means to directly probe the material temperature below the surface of an alloy while it is being processed are limited. To address this gap in characterization capabilities, a novel means is presented to extract subsurface temperature-distribution metrics, with uncertainty, from in situ synchrotron X-ray diffraction measurements to provide quantitative temperature evolution data during laser melting. Temperature-distribution metrics are determined using Gaussian process regression supervised machine-learning surrogate models trained with a combination of mechanistic modeling (heat transfer and fluid flow) and X-ray diffraction simulation. The trained surrogate model uncertainties are found to range from 5 to 15% depending on the metric and current temperature. The surrogate models are then applied to experimental data to extract temperature metrics from an Inconel 625 nickel superalloy wall specimen during laser melting. The maximum temperatures of the solid phase in the diffraction volume through melting and cooling are found to reach the solidus temperature as expected, with the mean and minimum temperatures found to be several hundred degrees less. The extracted temperature metrics near melting are determined to be more accurate because of the lower relative levels of mechanical elastic strains. However, uncertainties for temperature metrics during cooling are increased due to the effects of thermomechanical stress.

36 MATERIALS SCIENCE↗

NASA NTRS1986

A Constitutive Model for the Inelastic Multiaxial Cyclic Response of a Nickel Base Superalloy Rene 80

The objective was to develop unified constitutive equations which can model a variety of nonlinear material phenomena observed in Rene 80 at elevated temperatures. A constitutive model was developed based on back stress and drag stress. The tensorial back stress was used to model directional effects; whereas, the scalar drag stress was used to model isotropic effects and cyclic hardening or softening. A flow equation and evolution equations for the state variables were developed in multiaxial form. Procedures were developed to generate the material parameters. The model predicted very well the monotonic tensile, cyclic, creep, and stress relaxation behavior of Rene 80 at 982 C. The model was then extended to 871, 760, and 538 C. It was shown that strain rate dependent behavior at high temperatures and strain rate independent behavior at the lower temperatures could be predicted very well. A large number of monotonic tensile, creep, stress relation, and cyclic experiments were predicted. The multiaxial capabilities of the model were verified extensively for combined tension/torsion experiments. The prediction of the model agreed very well for proportional, nonproportional, and pure shear cyclic loading conditions at 982 and 871 C.

Ramaswamy, V. G.↗

NASA NTRS1987

An experimental evaluation of apparent strain from foil strain gauges attached to carbon composite substrates

An experimental evaluation of apparent thermal strains is conducted using various combinations of substrate/gauge/attachment structure and redundant high temperature extensometry. It is found that the extensometry could either confirm independent measurements of the substrate's thermal expansion, or quantify nonzero mechanical strains resulting from uncertain material behavior and boundary conditions. Apparent strain and thermal expansion behavior data can then be used to modify the raw strain measurements in order to determine either stress producing or total strains. Limitation of the correction procedure for the three selected strain gauges is noted which is due to relatively large gauge/attachment variability.

Scott, B. R.↗

NASA NTRS1987

Preliminary study of creep thresholds and thermomechanical response in Haynes 188 at temperatures in the range 649 to 871 C

The following conclusions were drawn from this study of creep thresholds and thermomechanical response: (1) creep threshold can be determined using the latest electrohydraulic test equipment, providing that test durations are short and relatively large accumulations of creep strain are used in defining the threshold; (2) significant creep strains were measured under monotonic loading as stress levels as low as 4 ksi at temperatures predicted for solar receiver service; and (3) the material exhibited creep ratchetting during simulated service cycles, a result not predicted by analysis using current constitutive models for Haynes 188.

Ellis, J. R.↗