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At least 37 records · Page 2

Unveiling the Fatigue Behavior of 2D Hybrid Organic–Inorganic Perovskites: Insights for Long-Term Durability

2D hybrid organic–inorganic perovskites (HOIPs) are commonly found under subcritical cyclic stresses and suffer from fatigue issues during device operation. However, their fatigue properties remain unknown. Here, the fatigue behavior of (C 4 H 9 -NH 3 ) 2 (CH 3 NH 3 ) 2 Pb 3 I 10 , the archetype 2D HOIP, is systematically investigated by atomic force microscopy (AFM). It is found that 2D HOIPs are much more fatigue resilient than polymers and can survive over 1 billion cycles. 2D HOIPs tend to exhibit brittle failure at high mean stress levels, but behave as ductile materials at low mean stress levels. These results suggest the presence of a plastic deformation mechanism in these ionic 2D HOIPs at low mean stress levels, which may contribute to the long fatigue lifetime, but is inhibited at higher mean stresses. The stiffness and strength of 2D HOIPs are gradually weakened under subcritical loading, potentially as a result of stress-induced defect nucleation and accumulation. The cyclic loading component can further accelerate this process. The fatigue lifetime of 2D HOIPs can be extended by reducing the mean stress, stress amplitude, or increasing the thickness. These results can provide indispensable insights into designing and engineering 2D HOIPs and other hybrid organic–inorganic materials for long-term mechanical durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

A non-melting additive approach to structural repair of aluminum aircraft fastener holes

The damage to fastener holes in aerospace aluminum structures presents significant challenges for aircraft durability, and conventional bushing methods for repairing oversized holes often fall short due to the lack of metallurgical bonding and limited edge distance availability. This study investigates additive friction stir deposition, a non-melting additive process, as a viable alternative for the structural repair of aerospace fastener holes. The repair process, demonstrated on AA7050 (Al-Zn-Mg-Cu-Zr) hole structures, involves filling oversized holes with new material and machining to restore the original hole size. The repaired hole coupons are defect-free and exhibit good fatigue performance under fully reversed tension-compression loading (R = -1). At a nominal stress amplitude of 123.5 MPa, the average number of cycles to failure is 12,666 for unrepaired baseline coupons and 17,372 for effectively repaired coupons. Restoring complex geometries without compromising fatigue performance has been difficult in aerospace applications; this study marks the first demonstration of additive repair that consistently outperforms the unrepaired baseline coupons. Notably, the result is achieved through a low-energy, cost-effective solution without the need for post-repair heat treatment. Except for a few outliers, the post-repair fatigue performance generally remains inferior to that of undamaged, pristine coupons, likely due to precipitate evolution in AA7050 caused by the thermomechanical processing nature of additive friction stir deposition. This evolution weakens the repair region and the adjacent base material, leading to faster crack initiation and growth compared to the properly aged base material, AA7050-T7451.

36 MATERIALS SCIENCE↗

Investigating the Interaction between Persistent Slip Bands and Surface Hard Coatings via Crystal Plasticity Simulations

Fatigue cracks often initiate from the surface extrusion/intrusions formed due to the operation of persistent slip bands (PSBs). Suppression of these surface topographical features by hard surface coatings can significantly extend fatigue lives under lower stress amplitudes (i.e., high cycle fatigue), while cracks initiate early in the coating or in the coating–substrate interface under higher stress amplitudes (i.e., low cycle fatigue), deteriorating the fatigue performance. However, both beneficial and detrimental effects of the coatings appear to be affected by the coating–substrate material combination and coating thickness. A quantitative understanding of the role of these factors in the fatigue performance of materials is still lacking. In this study, crystal plasticity simulations were employed to elucidate the dependence of the coating’s effects on two factors—i.e., the coating thickness and loading amplitudes. The results revealed that the thicker coatings more effectively suppress the operation of the PSBs, but generate higher tensile and shear stresses, normal and parallel to the interfaces, respectively, promoting interfacial delamination. The tensile stresses parallel to the interface within the coating, which favors coating fracture, are not sensitive to the coating thickness.

36 MATERIALS SCIENCE↗

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Submerged Fatigue Testing of Marine Energy Advanced Materials: Preprint

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Submerged Fatigue Testing of Marine Energy Advanced Materials

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. Finally, the benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

13 HYDRO ENERGY↗

Multiobjective Dynamic Optimization for Optimal Load-Following of Natural Gas Combined Cycle Power Plants under Stress Constraints

With the increasing penetration of intermittent renewable energy sources into the electric grid, there is an associated need for conventional thermal power plants that are designed to operate at base-load conditions to cycle their load rapidly and frequently and operate under low-load conditions. Fast load-following operations lead to plant efficiency loss and the reduction of equipment life. A high-fidelity dynamic model of a natural gas combined cycle power plant, with rigorous equipment level submodels, is developed to capture the plant transient performance and the thermomechanical stress evolution at the high-pressure drum is computed to assess the drum life consumption. Stress evolution is modeled for the location of the edge at the drum/downcomer junction that experiences high circumferential stress amplitude during the fast load-following operation, leading to higher fatigue damage than locations considered under existing design standards. A dynamic optimization problem is solved for optimal load-following operation. Depending on the value of the stress constraint and the desired ramp rate, satisfying the desired stress constraint may be infeasible without relaxing the ramp rate. A multiobjective dynamic optimization problem is solved using a lexicographic approach that minimizes ramp rate relaxation and maximizes efficiency while satisfying stress constraints, avoiding spraying to saturation, and maintaining main steam and reheat steam temperature within bounds. It was observed that the optimal ramp rate can be highly nonlinear as opposed to the industry-standard linear ramp rate. Nonlinear optimal ramp-rate profiles not only help to avoid stress constraints that may be unavoidable by using the linear profile but also result in higher efficiency than the linear profile. Furthermore, the study shows that there is a strong tradeoff between the relaxation in the plant ramp rate and the time-average thermal efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Heterogeneous fatigue damage in a nickel-based single-crystal superalloy unraveled using correlative 3D X-ray technology

Nickel-based single-crystal (Ni-SX) superalloys under cyclic stress are susceptible to cracking at stress-concentration sites, eventually leading to low-cycle fatigue (LCF) failure. LCF cracks typically originate from intrinsic defects (e.g., voids and carbides) within solidified dendrites. However, systematic quantitative experimental analyses of defect-mediated local damage remain limited. To thoroughly understand the microscopic origins and evolution of LCF damage, correlated 3D mapping of dendrites across various regions is essential. Here, in this study, macroscale micro-computed tomography (μ-CT) was initially used to capture internal interdendritic secondary cracks within bulk DD413 superalloy after LCF testing at 760 °C. Subsequently, a multimodal methodology combining synchrotron 3D microdiffraction (3D-μXRD), high-resolution μ-CT, and electron microscopy was established. This approach allowed precise localization of internal damage zones near interdendritic secondary cracks and detailed mapping of the 3D correlated distributions of dendrites, defects, and residual stress/strain fields within these zones at submicron spatial resolution. Finally, the same approach was applied to specimens subjected to interrupted loading at approximately 40 % of the fatigue life to uncover the early damage states of dendrites. The dendrite cores (DCs) and interdendritic regions (IDs) exhibit microscale heterogeneous mechanical responses: nearly defect-free DCs accumulate local irreversible slip along specific slip systems to generate slip bands, while the IDs containing various defects accommodate local microplasticity through the activation of multiple slip systems around these defects. The local tensile stress near defects in the IDs exceeds that in the DC slip band regions by more than threefold, leading to the generation of local damage zones within the IDs. Chain-like defect distributions facilitate the interconnection of these local zones into a continuous damage region, further elevating the overall tensile stress in the IDs. Additionally, geometrically necessary dislocations alone are insufficient as indicators of LCF damage; both the internal stress state and its magnitude must be considered. These experimental results provide critical data and insights for the development of multi-physics fatigue models.

Localized deformation↗

Draft Rules for Alloy 617 Creep-Fatigue Design Using an EPP+SMT Approach

The report describes an improved new creep-fatigue design method for structural components in high temperature nuclear service. The new method uses an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that greatly simplifies the design process by avoiding the separate evaluation of creep and fatigue damages and eliminating the requirement of stress classification. The report includes draft design rules, presented in a format compatible with an ASME nuclear Code Case, as well as a commentary on the rules and the validation of the rules using pressurized SMT (p-SMT) test data. Areas of potential improvement have been identified for further evaluation. The report also develops EPP+SMT design charts for Alloy 617 at temperatures between 800°C and 950°C by extrapolating high strain range, short hold test data to low strain range and long hold times, typical for structural components in high temperature nuclear service. The design charts are currently limited to 10,000 cycles to avoid excessive extrapolation outside the test database. More robust alternate extrapolation procedures will be considered in future work. The report includes several verification problems comparing the new EPP+SMT design method with current ASME creep-fatigue design methods. The comparison demonstrates that the EPP+SMT method significantly reduces the over-conservatism in current methods. Finally, the report includes a fully-documented sample problem with multiple load cases detailing the application of proposed EPP+SMT design rules.

36 MATERIALS SCIENCE↗

Hysteresis-Free Nanoparticle-Reinforced Hydrogels

The elastic storage and release of mechanical energy has been key to many developments throughout the history of mankind. Resilience, absent hysteresis, has been an elusive goal to achieve, particularly at large deformations. Using a low-crosslink-density polyacrylamide hydrogel at 96% water content having hyperbranched silica nanoparticles (HBSPs) as the major junction points, a hysteresis-free material is realized. The fatigue-free characteristic of these composite hydrogels is evidenced by the invariance of the stress–strain curves at strain ratios of 4, even after 5000 cycles. At a strain ratio of 7, only a 1.3% hysteresis is observed. A markedly increased strain-ratio-at-break of 11.5 is observed. Finally, the unique attributes of these resilient hydrogels are manifested in the high-fidelity detection of dynamic deformations under cyclic loading over a broad range of frequencies, difficult to achieve with other materials.

36 MATERIALS SCIENCE↗

Structural Characterization of Deployed Thermoplastic and Thermoset Composite Tidal Turbine Blades

The National Renewable Energy Laboratory worked with Verdant Power to manufacture, and characterize, novel thermoplastic composite blades on their Gen5d 5 m diameter turbines at the Roosevelt Island Tidal Energy (RITE) site in the East River in N.Y. to demonstrate a low-cost manufacturing process for marine energy structures. Verdant had designed, manufactured, and deployed epoxy thermoset composite blades on three Gen5d turbines in October 2020. At a maintenance cycle in May 2021, a Gen5d turbine equipped with the NREL thermoplastic blades was deployed and retrieved in October 2021. Modal, static and fatigue structural characterization was performed on both blade types before and after the deployment. The static and modal test results showed that the thermoplastic blades were slightly stiffer than the epoxy blades both dry and after the deployment. The epoxy blades had about 8% increase in strain at the applied load after the deployment, whereas the thermoplastic blade strains were not changed significantly. Ultimately the thermoplastic blade failed during fatigue testing due to a crack which is thought to have initiated between the internal foam and the laminate at the location of the internal instrumentation. The Verdant Power Gen5d epoxy blades did not have this internal instrumentation and did not have this failure, performing adequately through the operational period. A lack of design information and fatigue data for both the thermoplastic laminates and the adhesive used means that further work is needed to fully understand his failure and the root cause analysis is ongoing. This paper provides details on the thermoplastic blade manufacturing, materials, test methodology and results.

17 WIND ENERGY↗

Support of the Development of EPP Plus SMT Design Method (FY2020 Test Results)

Experiments in support of the development of the integrated Elastic–Perfectly Plastic (EPP) analysis and Simplified Model Test (SMT) design methodology continued in FY 2020. The previously developed single-bar SMT (SBSMT) technique was successfully extended to tubular shaped Alloy 617 specimens for evaluation of the effect of primary pressure load on SMT creep-fatigue (CF) properties at 950°C. A series of pressurized SMT tests were performed with various elastic follow-up factors and strain ranges. The results show that the primary pressure load reduces the SMT CF cycles. The reduction of SMT CF life due to primary load was found to be dependent on strain ranges, elastic follow up and test temperatures. These results are crucial for verification of the EPP strain range analysis in the EPP+SMT evaluation procedure. Additionally, hold time effect on the SMT CF life cycles is a determining factor for generating the EPP+SMT CF design curves. Lack of test data in the high cycle and low strain range region results in major uncertainty in developing the design curves. In FY2020, experiments were designed, and testing started on Alloy 617 at 950°C to fill the gap in experimental data. The on-going CF and additional SMT CF with elastic follow-up at low strain ranges will generate the information needed to verify the methods for extrapolation to long hold time and finalize the EPP+SMT design method.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Assessment of frequency and amplitude dependence on the cyclic degradation of polyurethane foams

Many energy absorption applications utilize flexible polymeric foams for their viscoelastic properties. It is desired that the material will perform consistently across repeated compression cycles. This study examines the effect of fatigue at low strain rates on the viscoelasticity of open-cell polyurethane foam. Six polyurethanes of the same base composition with two porosities (70% and 80%) and three chemical indexes (79i, 100i, and 121i) are tested. Large deformation cyclic compression of the foams is conducted on a universal testing system (UTS). These data are then post-processed leveraging dynamic mechanical analysis Fourier transform rheology to characterize changes in the viscoelasticity of the materials over fatigue cycles. Results show that foams can increase or decrease in stiffness up to 10% over 10 4 cycles. Specifically, higher chemical index, higher excitation frequency, and larger excitation amplitude correlate with a more pronounced decrease in stiffness. Damping can also change by 15% and correlates with chemical index and excitation frequency. Consequently, the findings suggest that internal foam structure and bulk material properties as well as applied loading parameters affect the viscoelastic fatigue response of flexible polymeric foams.

36 MATERIALS SCIENCE↗

Bamboo Bio-composite Truck/Trailer Decking

Bamboo is one of the fastest growing plants in the world. Massively productive, bamboo will maintain that productivity with limited inputs and minimal management resulting in predictable volume and operating margins and with low overhead. The goal of this project was to develop a bamboo bio-composite trailer decking product that replaces apitong, is lighter weight, stronger and luminescent. The collaboration partners, Fontaine, Resource Fiber and IACMI, worked closely to develop the bamboo bio-composite decking to Fontaine Trailer’s (end-user) specifications. The various technological objectives were (a) To conduct a comprehensive Design of Experiments study for bamboo composites to understand the structure-property relationships for different resin composites and bamboo forms (strips, woven, bulk etc); (b) To establish the nail pull out characteristics of trailer deck geometry bamboo composite form. The nail pull out is a critical test in trailer decks; (c) To design, process and prototype select number of trailer decking planks for Fontaine evaluation; and (d) To conduct life cycle analysis to conduct energy calculations from the various conversion steps of the bamboo from crop to product. The project meets DOE/IACMI metrics of reduced embodied energy, lightweighting and lowering the cost of the end product. It also offers a green solution to a value-added application, i.e. trailer decking. The development goals and benefits of bamboo composite decking included: A. Decreased weight when compared to Apitong and Gen 1, thereby reducing operating costs and petroleum usage due to increased miles per gallon. B. Flexibility to allow camber design into trailers. C. Luminescence to increase safety during low light and dark conditions. D. Composite material to maximize use of bamboo bio-composites as substitute for petroleum-based composites. E. Embedded layer(s) of conditioned bamboo for added strength and stability. F. Improved safety over Apitong by temporary cargo indentation in planks for better stability. G. Cradle-to-cradle design so end-of-life becomes beginning-of-life for other products. Resource Fiber’s bamboo biocomposite trailer decking passed nail pullout tests as compared to apitong (incumbent), was lighter weight than apitong, and used less embodied energy particularly when bamboo is sourced domestically. The planks were optimized in the lab setting to the extent possible and successfully installed on the trailer at Fontaine for field testing. Despite the process not being fully optimized due to through-heat and tooling limitations within the budget constraints, the prototype decking withstood 400 cycles of reverse fatigue loading of a 107,000 lb Caterpillar 349F which was extreme conditions of field testing by Fontaine Trailer. Resource Fiber plans to outsource production of a next round of planks with a commercial pultrusion processor, then to do a re-test with Fontaine Trailers. Tooling specific to the part is required. Long-term commercial plans are to continue outsourcing production while supplying bamboo fiber and mats. Commercial markets include heavy haul trailers, military trailers, and decking for marine, industrial and residential use.

36 MATERIALS SCIENCE↗

Effects of Coatings on Water Intrusion and Strain Gauge Durability in Submerged Fatigue Conditions: Preprint

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand the combined effects of moisture intrusion and mechanical fatigue on marine energy structures, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Measuring strain is critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions was not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure, strains, and strain gauge failure modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite fatigue testing↗

Effects of Strain Gauge Coatings on Water Intrusion in Submerged Composite Coupon Testing

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand their combined effects, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Strain measurements are critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions is not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure (SGF), strains, and SGF modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The coatings did not have significant effects on composite fatigue life or strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

Abnormal grain growth of 68Cu–16Al–16Zn alloys for elastocaloric cooling via cyclical heat treatments

Abstract Cu-based superelastic shape memory alloys are promising for low-stress elastocaloric cooling. We have synthesized bulk alloys of 68Cu–16Al–16Zn under different conditions in order to promote its grain growth and enhance its elastocaloric properties. High-temperature x-ray diffraction of untreated 68Cu–16Al–16Zn alloy showed that the phase boundary between the α + β mixed phases and the high temperature phase ( β phase) was between 973 K and 1023 K. Based on this result, the 68Cu–16Al–16Zn alloy was heated and cooled in a furnace repeatedly between 773 K and 1173 K. The maximum grain size after heat treatment of the ingot rolled to 67% reached 11.1 mm. The latent heat of the martensitic transformation after grain growth was 6.3 J g −1 , which is higher than the previously reported value for the compound. The stress–strain curve of 68Cu–16Al–16Zn rolled to 67% rolling with cyclical heat treatments showed a maximum stress of 106 MPa at 4.5% strain, with adiabatic temperature change of 5.9 K in heating during stress loading and 5.6 K in cooling in stress removal. Furthermore, no fatigue in the stress–strain behavior was observed up to at least 60 000 mechanical cycles at 2% strain.

36 MATERIALS SCIENCE↗