Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “material strength”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

A novel physics-based and data-supported microstructure model for part-scale simulation of laser powder bed fusion of Ti-6Al-4V

The elasto-plastic material behavior, material strength and failure modes of metals fabricated by additive manufacturing technologies are significantly determined by the underlying process-specific microstructure evolution. In this work a novel physics-based and data-supported phenomenological microstructure model for Ti-6Al-4V is proposed that is suitable for the part-scale simulation of laser powder bed fusion processes. The model predicts spatially homogenized phase fractions of the most relevant microstructural species, namely the stable β-phase, the stable α s -phase as well as the metastable Martensite α m -phase, in a physically consistent manner. In particular, the modeled microstructure evolution, in form of diffusion-based and non-diffusional transformations, is a pure consequence of energy and mobility competitions among the different species, without the need for heuristic transformation criteria as often applied in existing models. The mathematically consistent formulation of the evolution equations in rate form renders the model suitable for the practically relevant scenario of temperature- or time-dependent diffusion coefficients, arbitrary temperature profiles, and multiple coexisting phases. Due to its physically motivated foundation, the proposed model requires only a minimal number of free parameters, which are determined in an inverse identification process considering a broad experimental data basis in form of time-temperature transformation diagrams. Subsequently, the predictive ability of the model is demonstrated by means of continuous cooling transformation diagrams, showing that experimentally observed characteristics such as critical cooling rates emerge naturally from the proposed microstructure model, instead of being enforced as heuristic transformation criteria. Eventually, the proposed model is exploited to predict the microstructure evolution for a realistic selective laser melting application scenario and for the cooling/quenching process of a Ti-6Al-4V cube of practically relevant size. Numerical results confirm experimental observations that Martensite is the dominating microstructure species in regimes of high cooling rates, e.g., due to highly localized heat sources or in near-surface domains, while a proper manipulation of the temperature field, e.g., by preheating the base-plate in selective laser melting, can suppress the formation of this metastable phase.

Inverse parameter identification↗
DOE OSTI2014

Low-Cost Efficient Manufacturing of Pressurized Conformable Compressed Natural Gas Storage Tanks

The project goal was to combine welding and superplastic forming (SPF) processes to develop a conformal pressure vessel with >90% conformability, >12 MJ/kg energy density, and <$\$$1500 tank cost. PNNL investigated an extensive set of geometries and materials showing that reinforcement geometries based on the Schwarz-P minimal surface spanning a volume produced the highest flexibility in tank geometry, conformability, and nearly met the energy density target (11.9 vs. 12 MJ/kg) based on Titanium 6Al-4V material strength. The idealized geometry proved very challenging to achieve using welding and SPF of either tubing or sheet metal. PNNL demonstrated that full Schwarz-P shapes could be formed from titanium tubing using hot metal gas forming. However, that approach was discontinued because of the many components which required joining to assemble a tank structure. Superplastic blow-forming of a welded, multi-sheet pack was further developed using PNNL’s E-beam welding and SPF capabilities. Several sheet-pack designs were welded and formed, culminating in a small demonstration tank designed to withstand the design burst pressure. X-rays confirmed that the modeled internal structure was achieved during forming. During pressure tested the tank leaked (short of the required burst pressure) at thin spots in irregular E-beam welds connecting the outer pressure boundary to the inner reinforcing layers. However, the tank did not burst and the flat sides of the conformal tank were maintained, confirming the integrity of the internal reinforcements. Further refinement of the weld energy and speed plus the control of an automated welding machine would improve weld quality and increase the pressure to leak or burst.

03 NATURAL GAS↗
DOE OSTI2015

Zero Degree Line Mo Target Thermal Test Results and Analysis

Target testing at 35 and 42 MeV was completed on January 14, 2015. At 35 MeV the current was varied from 177 to 375 μA with helium mass flow rate varied from 45 up to 101 g/s. At 42 MeV only one current, 170 mA, was tested because of accelerator performance limitations. The target design for this test, and the subsequent production tests, is largely unchanged from the earlier design for ANL beam tests at lower energy and higher current, comprised of 25 Mo disks 1 mm thick spaced 0.5 mm apart for helium coolant flow gaps. Disks are 12 mm diameter, with expected beam size 6 mm FWHM. Because the target, particularly the window, was designed for lower energy and higher current, the intercepted beam (beam heating) was much less during these tests. Therefore, the thermal stress and, more importantly, reduction in material strength resulting from high temperature, was not a limiting concern. The intended result of the thermal test is to measure heat transfer as a function of helium mass flow rate. Heat transfer coefficient was determined by the measurement of temperature at the center of the first 8 Mo disks while varying helium flow rate and beam current. The performance was then compared to predictive tools: Heat transfer correlations in the literature and finite element analysis using ANSYS

42 ENGINEERING↗
DOE OSTI2018

Return on Investment (ROI) Framework Case Study: CTH.

CTH is a Eulerian code developed at Sandia National Laboratories capable of modeling the hydrodynamic response of explosives, liquids, gases, and solids. The code solves complex multi-dimensional problems characterized by large deformations and strong shocks that are composed of various material configurations. CTH includes models for material strength, fracture, porosity, and high explosive detonation and initiation. The code is an acronym for a complex series of names relating to its origin. A full explanation can be seen in Appendix A. The software breaks penetration simulations into millions of grid-like “cells”. As a modeled projectile impacts and penetrates a target, progressively smaller blocks of cells are placed around the projectile, which show in detail deformations and breakups. Additionally, the code is uniquely suited to modeling blunt impact and blast loading leading to human body injury.

42 ENGINEERING↗
DOE OSTI2020

Technology Demonstration of a High-Pressure Swirl Oxy-Coal Combustor

This technical report presents the exploration of the design and prototyping of a High-Pressure Swirl Oxy-coal Combustor. Pressurized oxy-coal combustion systems have the potential to improve efficiency along with an increased carbon capture rate. Reduction of flue gas at higher pressure, smaller system size, and capital cost reductions render high-pressure oxy-coal systems particularly attractive as next-generation energy-producing systems. High-pressure oxy-coal combustion systems are a recent concept, and thus operability issues of combustor designs for such systems are not fully understood. Significant challenges exist to maintain oxy-coal combustion stability at elevated pressure and a high CO 2 diluent environment. Although a body of knowledge exists for high-pressure oxygen combustion in rocket engines (or similar applications), it is yet to be strategized how these fundamental concepts can be translated to low-temperature CO 2 diluent combustion regimes. The realization of the pressurized oxy-coal based systems requires combustor components to be designed and demonstrated for an operating pressure over 10 bar. However, pressurized oxy-coal combustor design information at this pressure range and scale relevant to validate those proposed systems is currently limited. Experimental data from MWth scale oxy-coal combustors are needed to identify the optimal trade-off between net efficiency and systems size. The proposed effort is aimed at demonstrating a 1 MWth down-fired swirl Oxy-Coal combustor and investigate the interrelation between combustor operating conditions (pressure; flame stability; flue gas recirculation ratio) and conversion efficiencies to minimize oxygen requirements. One of the key challenges is to configure burner design (i.e., swirl number and injector) and operating conditions for high-pressure oxy-coal combustion systems. These experiments differ from current systems partly due to the high theoretical flame temperature and related burner operability issues associated with oxy-combustion. An ASPEN PLUS® model study for 550 MWe TIPS and ENEL pressurized oxy-coal systems with CO 2 recirculation was performed to evaluate system design, subsystems sizing, and operating condition determination. The system analysis effort included TRL and technology gap determination of subsystems and critical components. This information was scaled to develop design requirements (design pressure and flue gas recirculation: RR Flue Gas = $\frac{m_{flue}}{m_{total}}$) for the 1 MWth combustor. The effects of a wide range of carbon dioxide recirculation ratios on the thermal efficiency of ENEL and TIPS cycles are studied. The pressure of 10 bar and 80 bar are used for ENEL and TIPS cycles, respectively. The thermal efficiency of ENEL is significantly higher than the efficiency of TIPS at a pressure of less than 10 bar. The insights from system analysis were then used to design a 1 MWth swirl oxy-coal combustor. Flame temperature analysis and material strength analysis was performed to determine the combustor thickness. The structural integrity of the combustor was validated by finite element analysis using Abacus® and Hypermesh®. Feasibility of igniters and secondary burners are investigated in successful high-pressure oxy-methane combustion. The secondary burners are designed in such a way that it can operate between 100 to 500 kW firing input. Three generations of the pintle injector were designed based on swirl numbers (S=0, 0.9, and 1.2). Key pintle injector parameters such as pintle size, pintle orifice size, spray pattern were investigated by cold flow tests. Information from these tests was used to modify injector design for smooth and successful operation. A 5 mm pintle orifice size was decided upon as the optimum size for oxy-coal operation for the combustor. Shadow sizing experiments were performed to identify the atomization rate of each injector. Different coal water slurry mixtures (30 – 50% coal by wt% in the mixture) at various total momentum ratios (TMR) were investigated for this purpose. These experiments provided decisive information to choose the best design of the injector. The injector with 1.2 swirl provided higher atomization in all cases than other designs. The mean equivalent droplet size of the jet was similar at different TMR and mixture ratios using this injector, thus making it suitable for use in most cases. Therefore, the 1.2 swirl-pintle injector was chosen for the shakedown test. The combustor and other sub-systems, including feed systems and control and data acquisition, have been manufactured, assembled, and integrated. The total system integration and installation began on July 1, 2020. The shake-down tests and initial operational capability demonstration are expected to be completed by September 30, 2020.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

UNR ETI Computational Investigation (Year 2)

The LANL ASC Arbitrary Lagrange/Eulerian (ALE) code, FLAG, is being used to model experiments conducted under this grant in order to understand the physics limiting high-current conduction and thermal plasma production. This includes the effects of nonlinear magnetic diffusion (NLMD), the magnetic Rayleigh-Taylor (MRT) instability, and the electro-thermal instability (ETI). FLAG is a multi-dimensional, unstructured-grid, multi-material, multi-temperature, shockphysics code with a single-fluid, resistive magnetohydrodynamics (MHD) package. Equations-ofstate (EOS), conductivity, material-strength, and melt can be treated with a variety of analytic or tabular models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

The Multiphysics on Advanced Platforms Project

In 2015, the Lawrence Livermore National Laboratory started development of next-generation multiphysics simulation capabilities for the National Nuclear Security Administration under the Advanced Technologies Development and Mitigation (ATDM) element of the Advanced Simulation and Computing program in collaboration with the Exascale Computing Project (ECP). A key driver for this effort across the NNSA tri-lab was the emergence of advanced high performance computing (HPC) architectures based on heterogeneous compute capabilities, including GPU based systems, as part of the national drive toward exascale computing platforms at multiple Department of Energy (DOE) facilities. Developing a multiphysics code capable of meeting the various simulation needs of the NNSA as defined by the current generation of integrated codes (or ICs), initially developed as part of the Accelerated Strategic Computing Initiative (ASCI) program beginning in 1996, and able to scale to the current 100 petaflop class pre-exascale systems, as well the forthcoming exaflop class computers, is a daunting challenge. To accomplish this ambitious goal, LLNL has embraced two key themes: use of high-order numerical methods and a modular approach to code development. The LLNL next generation effort is organized under the Multi-Physics on Advanced Platforms Project (MAPP). A foundational component of MAPP is the Axom computer science (CS) toolkit which provides infrastructure for the development of modular, performance portable, multi-physics application codes. MARBL is a next-generation application code built on the Axom base to address the modeling needs of the high energy density physics (HEDP) community for simulating high-explosive, magnetic or laser driven experiments such as inertial confinement fusion (ICF), pulsed-power magneto-hydrodynamics (MHD), equation of state (EOS) and material strength studies as part of the NNSA’s stockpile stewardship program (SSP).

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

2D Magnetohydrodynamic Simulations of the Electrothermal Instability in Metallic Liners

The Virginia Tech (VT) Plasma Dynamics Laboratory Computational (PDCL) and Lawrence Livermore National Laboratory (LLNL) are performing two dimensional (2D) simulations of the electrothermal instability (ETI) using the LLNL multi-physics code Ares. Ares is a multi-physics arbitrary–Lagrangian-Eulerian (ALE) code developed by LLNL and is of particular use in studying magnetohydrodynamic (MHD) instabilities like the ETI due to its resistive MHD, magnetic diffusion, and radiative-hydrodynamics packages. Among its capabilities, it has the ability to model material strength, perform adaptive mesh refinement (AMR), and incorporate a wide variety of equations of state models and conductivity models. The 2D Ares simulation model created by VT-LLNL for studying the development and growth of the electrothermal instability has been configured with initial conditions based on the Mykonos Electrothermal Instability II (METI-II) experiments described by this grant and conducted by team members at the University of Nevada (UNR), the University of New Mexico (UNM), and Sandia National Laboratories. Previously, preliminary 2D Ares simulations of the ETI had been run to approximately 80ns. The rods in these simulations were initiated with sinusoidal perturbations at a similar order of magnitude to those measured on the aluminum rods used for the Mykonos experiment. This model has been improved by increasing the spatial resolution of the simulations and running the simulations further in time. In addition to the simulation run-times extending, the preliminary sinusoidal perturbation has been replaced with a perturbation derived from amplitude measurements by the experimental team, thereby correlating the simulation inputs better to the experimental runs. These new runs are capable of reaching 120ns of simulated time for the uncoated cases and to 200ns the 41 μm coated cases.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Advanced Physics Models for Particle-Particle Interactions (UCD final report)

The LDRD "Advanced Physics Models for Particle-Particle Interactions” collaborative research with Professor Jennifer Sinclair Curtis and PhD student Chanh Nguyen at the University of California, Davis involved meso-scale, discrete element method (DEM) modeling of micron-sized particles impacting a substrate. Using DEM, physical insight into the details of particle response upon impact can be obtained. Such details provide the type of information necessary to enhance existing continuum or macro-scale simulation tools so that modeling for material strength and particle breakage models is based on particle physics versus empirical relationships. While molecular dynamics simulations of atoms can also provide physical insight into the particle response to impact, the scale of particles that are treated is on the order of angstroms, not microns. This study gives evidence to the ability of the DEM simulation technique to provide such fundamental, detailed insight for micron-sized particles as a function of particle properties and impact velocity.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Quantum-Accurate Multiscale Modeling of Shock Hugoniots, Ramp Compression Paths, Structural and Magnetic Phase Transitions, and Transport Properties in Highly Compressed Metals

Fully characterizing high energy density (HED) phenomena using pulsed power facilities (Z machine) and coherent light sources is possible only with complementary numerical modeling for design, diagnostic development, and data interpretation. The exercise of creating numerical tests, that match experimental conditions, builds critical insight that is crucial for the development of a strong fundamental understanding of the physics behind HED phenomena and for the design of next generation pulsed power facilities. The persistence of electron correlation in HED materials arising from Coulomb interactions and the Pauli exclusion principle is one of the greatest challenges for accurate numerical modeling and has hitherto impeded our ability to model HED phenomena across multiple length and time scales at sufficient accuracy. An exemplar is a ferromagnetic material like iron, while familiar and widely used, we lack a simulation capability to characterize the interplay of structure and magnetic effects that govern material strength, kinetics of phase transitions and other transport properties. Herein we construct and demonstrate the Molecular-Spin Dynamics (MSD) simulation capability for iron from ambient to earth core conditions, all software advances are open source and presently available for broad usage. These methods are multi-scale in nature, direct comparisons between high fidelity density functional theory (DFT) and linear-scaling MSD simulations is done throughout this work, with advancements made to MSD allowing for electronic structure changes being reflected in classical dynamics. Main takeaways for the project include insight into the role of magnetic spins on mechanical properties and thermal conductivity, development of accurate interatomic potentials paired with spin Hamiltonians, and characterization of the high pressure melt boundary that is of critical importance to planetary modeling efforts.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Experiments and Simulations of the Dusty Properties of Hypervelocity Impact Plasmas

Hypervelocity impacts, referring to impacts occurring at several times the speed of sound in the target, result in inertial stresses greatly exceeding the material strength and produce behavior that is not fully understood. These impact phenomena are seen in space through impacts of orbital debris and meteoroids on spacecraft and airless natural bodies but can also be produced in laboratory environments using light-gas guns and electrostatic dust accelerators. When a hypervelocity impact occurs, plasma is generated both from thermal ionization and from pressure ionization, producing a wide range of plasma densities depending on the impactor’s velocity. This plasma is initially formed in the warm dense matter (WDM) regime and governed by high energy density (HED) hydrodynamics before it rapidly expands and dissipates, spanning many orders of magnitude in density and length scale. The plasma can also contain a dust component, which is particularly relevant for the lower-velocity range of hypervelocity impacts with parameters that are particularly relevant to Tokamak plasmas. Therefore, the properties and dynamics of these plasmas cannot be fully characterized without considering dusty plasma effects, which are ubiquitous but poorly understood.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Development of a reliable Potting process for Photoconductive Semiconductor Switches (PCSS)

Electrical potting is an important process to protect semiconductor devices from damaging external elements (mechanical stress, moisture, high voltage, etc.) and provides structural support for delicate devices for electrical connectivity to a larger platform. This internship will focus on the development of a universal potting jig for photoconductive semiconductor switches (PCSS). The goal is to design a reliable compression jig that is cross compatible with various PCSS designs that allow for easy potting of devices with a high dielectric breakdown strength material. The challenge with the current potting jig is that the design is only compatible with one style of PCSS and applies uneven pressure that can lead to leakage of potting material. Our approach is to move from a design that applies pressure by binder clip to utilizing a micrometer based compressing jig for a reliable packaging process that can pot a variety of devices without having to have a unique compressing jig for each of style of PCSS. Possible roadblocks with the new design include epoxy leakage into the optical path and misalignment of the electrode – metal contact bond.

42 ENGINEERING↗
DOE OSTI2016

Constraints on planetesimal collision models in debris disks

Observations of debris disks offer a window into the physical and dynamical properties of planetesimals in extrasolar systems through the size distribution of dust grains. In particular, the millimeter spectral index of thermal dust emission encodes information on the grain size distribution. We have made new VLA observations of a sample of seven nearby debris disks at 9 mm, with 3{sup ′′} resolution and ∼5 μJy beam{sup −1}rms. We combine these with archival ATCA observations of eight additional debris disks observed at 7 mm, together with up-to-date observations of all disks at (sub)millimeter wavelengths from the literature, to place tight constraints on the millimeter spectral indices and thus grain size distributions. The analysis gives a weighted mean for the slope of the power-law grain size distribution, n(a)∝a{sup −q}, of 〈q〉=3.36±0.02, with a possible trend of decreasing q for later spectral type stars. We compare our results to a range of theoretical models of collisional cascades, from the standard self-similar, steady-state size distribution (q = 3.5) to solutions that incorporate more realistic physics such as alternative velocity distributions and material strengths, the possibility of a cutoff at small dust sizes from radiation pressure, and results from detailed dynamical calculations of specific disks. Such effects can lead to size distributions consistent with the data, and plausibly the observed scatter in spectral indices. For the AU Mic system, the VLA observations show clear evidence of a highly variable stellar emission component; this stellar activity obviates the need to invoke the presence of an asteroid belt to explain the previously reported compact millimeter source in this system.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1962

Observations on Cavitation Damage in a Flowing System

Cavitation damage to specimens of stainless steel, carbon steel, aluminum, and plexiglas, placed in a cavitating venturi using water and mercury as test fluids is mostly in the form of irregularly shaped pits which do not change with additional exposure to the cavitating field within the limited durations utilized. The rate of damage is very high initially, decreases for a relatively short period of time, then increases again up to the maximum test durations of 150 hours with water and 270 hours with mercury. Observation of damage effects by several independent techniques, using a variety of specimen materials, with two different fluids under various fluid dynamic conditions, leads to a suggested correlating model in terms of the cavitation bubble density and energy and specimen material strength.

VENTURI TUBE↗
NASA NTRS1970

Oxidation resistant iron and nickel alloys for high temperature use

Iron-base and nickel-base alloys exhibit good oxidation resistance and improved ductility with addition of small amounts of yttrium, tantalum /or hafnium/, and thorium. They can be used in applications above the operating temperatures of the superalloys, if high strength materials are not required.

Hill, V. L.↗