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DOE OSTI2021

Imaging of surface acoustic waves on GaAs using 2D confocal Raman microscopy and atomic force microscopy

Surface acoustic wave devices have been fabricated on a GaAs (100) substrate to demonstrate the capability of 2D Raman microscopy as an imaging technique for acoustic waves on the surface of a piezoelectric substrate. Surface acoustic waves are generated using a two-port interdigitated transducer platform, which is modified to produce surface standing waves. We have derived an analytical model to relate Raman peak broadening to the near-surface strain field of the GaAs surface produced by the surface acoustic waves. Additionally, atomic force microscopy is used to confirm the presence of a standing acoustic wave, resolving a total vertical displacement of 3 nm at the antinode of the standing wave. Stress calculations are performed for both imaging techniques and are in good agreement, demonstrating the potential of this Raman analysis.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Bendability parameter for twisted ribbons to describe longitudinal wrinkling and delineate the near-threshold regime

We propose a dimensionless bendability parameter, ε -1 =[(h/W) 2 ⁢T -1 ] -1 , for wrinkling of thin, twisted ribbons with thickness h, width W, and tensional strain T. Bendability permits efficient collapse of data for wrinkle onset, wavelength, critical stress, and residual stress, demonstrating longitudinal wrinkling's primary dependence on this parameter. This parameter also allows us to distinguish the highly bendable range (ε -1 >20) from moderately bendable samples (ε -1 ϵ(0,20]). We identify scaling relations to describe longitudinal wrinkles that are valid across our entire set of simulated ribbons. When restricted to the highly bendable regime, simulations confirm theoretical near-threshold (NT) predictions for wrinkle onset and wavelength.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Impact of Plate Thickness and Joint Geometry on Residual Stresses in 347H Stainless Steel Welds

Weldments of 347H stainless steel are potentially susceptible to stress relaxation cracking at elevated service temperatures. Mitigation of stress relaxation cracking susceptibility within a multipass weld requires a good understanding of welding practices and manufacturing techniques to control high tensile residual stresses. Here in this work, the dependence of residual stress distribution in 347H stainless steel on base plate thickness, joint geometry design, and preheating condition was systematically investigated by using three-dimensional finite element models. The finite element models were validated through good agreement between neutron diffraction measurements and calculated elastic strains. The single-V-groove welds with and without a preheating step all produced similar peak von Mises residual stresses, above 450 MPa, within both the fusion zone and heat-affected zone (HAZ). In plates thicker than 0.5 in. (12.7 mm), high tensile residual stress could be observed in a relatively large area, from the middle of the plate thickness to underneath the top surface. A double-V groove shifted the high tensile stress area to the middle thickness of the weld. A single-J-groove weld was able to confine the residual stress to a very small region near the middle thickness within the fusion zone and suppressed the von Mises residual stress within the HAZ to below 400 MPa.

14 SOLAR ENERGY↗

NASA NTRS1992

Creep behavior of tungsten fiber reinforced niobium metal matrix composites

Tungsten fiber reinforced niobium metal matrix composites were evaluated for use in space nuclear power conversion systems. The composite panels were fabricated using the arc-spray monotape technique at the NASA Lewis Research Center. The creep behavior of W/Nb composite material was determined at 1400 and 1500 K in vacuum over a wide range of applied loads. The time to reach 1 percent strain, the time to rupture, and the minimum creep rate were measured. The W/Nb composites exceeded the properties of monolithic niobium alloys significantly even when compared creep strength also was evaluated. Kirkendall void formation was observed at the fiber/matrix interface; the void distribution differed depending the fiber orientation relative to the stress axis. A relationship was found between the fiber orientation and the creep strength.

Grobstein, Toni L.↗

NASA NTRS1999

Fiber Optic Sensor Components and Systems for Smart Materials and Structures

The general objective of the funded research effort has been the development of discrete and distributed fiber sensors and fiber optic centered opto-electronic networks for the intelligent monitoring of phenomena in various aerospace structures related to NASA Marshall specific applications. In particular, we have proposed and have been developing technologies that we believe to be readily transferrable and which involve new fabrication techniques. The associated sensors developed can be incorporated into the matrix or on the surfaces of structures for the purpose of sensing stress, strain, temperature-both low and high, pressure field variations, phase changes, and the presence of various chemical constituents.

Lyons, R.↗

NASA NTRS2017

Insights into the Behavior of Potential Structural Failures Originating from Localized High Stress Regions in Configurations Relevant to Solid Rocket Motor Nozzles

During the structural certification effort for the Space Launch System solid rocket booster nozzle, it was identified that no consistent method for addressing local negative margins of safety in non-metallic materials had been developed. Relevant areas included bond-line terminations and geometric features in the composite nozzle liners. In order to gain understanding, analog test specimens were designed that very closely mimic the conditions in the actual full scale hardware. Different locations in the nozzle were represented by different analog specimen designs. This paper describes those tests and corresponding results. Finite element analysis results for the tests are presented. Strain gage correlation of the analysis to the test results is addressed. Furthermore, finite fracture mechanics (a coupled stress and energy failure criterion) is utilized to predict the observed crack pop-in loads for the different configurations. The finite fracture mechanics predictions are found to be within a 10% error relative to the average measured pop-in load for each of four configurations. Initiation locations, arrest behaviors, and resistances to further post-arrest crack propagation are also discussed.

McCutcheon, David Matthew↗

NASA NTRS1994

Characterization of Metal Matrix Composites

Experimental methods were developed, adapted, and applied to the characterization of a metal matrix composite system, namely, silicon carbide/aluminim (SCS-2/6061 Al), and its constituents. The silicon carbide fiber was characterized by determining its modulus, strength, and coefficient of thermal expansion. The aluminum matrix was characterized thermomechanically up to 399 C (750 F) at two strain rates. The unidirectional SiC/Al composite was characterized mechanically under longitudinal, transverse, and in-plane shear loading up to 399 C (750 F). Isothermal and non-isothermal creep behavior was also measured. The applicability of a proposed set of multifactor thermoviscoplastic nonlinear constitutive relations and a computer code was investigated. Agreement between predictions and experimental results was shown in a few cases. The elastoplastic thermomechanical behavior of the composite was also described by a number of new analytical models developed or adapted for the material system studied. These models include the rule of mixtures, composite cylinder model with various thermoelastoplastic analyses and a model based on average field theory. In most cases satisfactory agreement was demonstrated between analytical predictions and experimental results for the cases of stress-strain behavior and thermal deformation behavior at different temperatures. In addition, some models yielded detailed three-dimensional stress distributions in the constituents within the composite.

Daniel, I. M.↗

NASA NTRS1993

Inelastic deformation of metal matrix composites

A theoretical model capable of predicting the thermomechanical response of continuously reinforced metal matrix composite laminates subjected to multiaxial loading was developed. A micromechanical model is used in conjunction with nonlinear lamination theory to determine inelastic laminae response. Matrix viscoplasticity, residual stresses, and damage to the fiber/matrix interfacial zone are explicitly included in the model. The representative cell of the micromechanical model is considered to be in a state of generalized plane strain, enabling a quasi two-dimensional analysis to be performed. Constant strain finite elements are formulated with elastic-viscoplastic constitutive equations. Interfacial debonding is incorporated into the model through interface elements based on the interfacial debonding theory originally presented by Needleman, and modified by Tvergaard. Nonlinear interfacial constitutive equations relate interfacial tractions to displacement discontinuities at the interface. Theoretical predictions are compared with the results of an experimental program conducted on silicon carbide/titanium (SiC/Ti) unidirectional, (O4), and angle-ply, (+34)(sub s), tubular specimens. Multiaxial loading included increments of axial tension, compression, torque, and internal pressure. Loadings were chosen in an effort to distinguish inelastic deformation due to damage from matrix plasticity and separate time-dependent effects from time-independent effects. Results show that fiber/matrix debonding is nonuniform throughout the composite and is a major factor in the effective response. Also, significant creep behavior occurs at relatively low applied stress levels at room temperature.

Lissenden, C. J.↗

DOE OSTI2022

Hybrid AI-ML and FE-based Digital Twin Predictive Modeling Framework for a PWR Coolant System Components: Updates on Multi-Time-Series-3D-Location Dependent Usages Factor Prediction

The long-term operation (LTO) of nuclear power plants (NPP) beyond their original design life of 40 years can lead to more material damage associated with cyclic fatigue under thermal-mechanical loading cycles and associated long-term exposure of reactor material to the deleterious reactor-coolant environments. However, under this LTO condition, the reactor components can still safely operate but may require more frequent Nondestructive Evaluation (NDE) of reactor components. Requiring frequent NDE inspections may lead to frequent NPP shutdowns which can lead to power outages and additional NDE inspection cost-related economic loss. The economic loss can be minimized by reducing uncertainty in life estimation of safety-critical pressure boundary components and by implementing a more digital approach such as using upcoming digital-twin (DT) technology for predicting the structural states (e.g., time and location dependent inside/outside thickness temperature, stress, strain, plastic deformation, etc.) and associated fatigue life of a component in real time. The DT framework is based on limited experimental data, Artificial-intelligence (AI)-Machine-Learning (ML) and multiphysics-computationalmechanics such as finite element- (FE) based models. Given the real-time thermal-hydraulic process measurements from several existing plant sensors, the overall goal of the DT framework is to predict the cumulative usages factors or equivalent fatigue lives in real time and at any random 3D location of the components. This includes inaccessible locations such as inside the thickness or location of a component. This prediction can be at thousands to millions of 3D point clouds or locations like conventional FE-based models, but without running an FE model in real time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2002

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction, which were not considered in the simplified computer models. The fatigue testing proved the value of redundancies since specimen strength was maintained even after the fracture of one or two ligaments. This ongoing test program is planned to continue through high-temperature testing. Also scheduled for testing are IN 718 lattice block panels with integral face sheets, as well as specimens cast from a higher temperature alloy. The initial testing suggests the value of this technology for large panels under low and moderate pressure loadings and for high-risk, damage-tolerant structures. Potential aeropropulsion uses for lattice blocks include turbine-engine actuated panels, exhaust nozzle flaps, and side panel structures.

Krause, David L.↗

NASA NTRS2012

Large-Scale Weibull Analysis of H-451 Nuclear- Grade Graphite Specimen Rupture Data

A Weibull analysis was performed of the strength distribution and size effects for 2000 specimens of H-451 nuclear-grade graphite. The data, generated elsewhere, measured the tensile and four-point-flexure room-temperature rupture strength of specimens excised from a single extruded graphite log. Strength variation was compared with specimen location, size, and orientation relative to the parent body. In our study, data were progressively and extensively pooled into larger data sets to discriminate overall trends from local variations and to investigate the strength distribution. The CARES/Life and WeibPar codes were used to investigate issues regarding the size effect, Weibull parameter consistency, and nonlinear stress-strain response. Overall, the Weibull distribution described the behavior of the pooled data very well. However, the issue regarding the smaller-than-expected size effect remained. This exercise illustrated that a conservative approach using a two-parameter Weibull distribution is best for designing graphite components with low probability of failure for the in-core structures in the proposed Generation IV (Gen IV) high-temperature gas-cooled nuclear reactors. This exercise also demonstrated the continuing need to better understand the mechanisms driving stochastic strength response. Extensive appendixes are provided with this report to show all aspects of the rupture data and analytical results.

Nemeth, Noel N.↗

NASA NTRSDate not supplied

Testing of ACC-6 Carbon-Carbon at High Strain Rates and High Temperatures

Some materials, such as steel, titanium, and tungsten, have a yield stress that depends on the strain rate, and actually are stronger at high rates of load or deformation. The increase in strength is relevant; and if not taken into account, the computer models will not match the experimental behavior observed in typical shock loading, ordnance, or ballistic tests. For higher velocity (hypervelocity impacts), an equation of state that accounts for non-linearities and temperature in the pressure-volume relation, may also be needed. This rate-dependent behavior of the strength has also been observed in some composite materials. Southwest Research Institute® (SwRI®) has started an internal research effort to measure and better model the behavior of materials, in particular carbon/carbon composites like ACC-6, at ultra-high temperatures for both static and high rates of deformation. The ultimate objective is to obtain reliable computer models of carbon/carbon material under hypersonic flight conditions, hypervelocity impacts, shock-loading situations such as booster-vehicle separation, and munition operation events. SwRI® has successfully modeled in the past ballistic impact on other composites, namely S-2 glass/epoxy, Kevlar/resin, polyethylene fibers/resin, and carbon fiber composites. This presentation will show test results relevant to the strength properties of the ACC-6 C/C material which were measured at quasistatic, medium, and the moderately high strain rates (~103 s—1) achievable in a conventional Split Hopkinson bar apparatus. Some of the tests were performed at both high-rates and high temperatures typical of hypersonic flight, something that, to the authors’ knowledge, has never been published in the past for this particular material. The test method will be presented, as well as the comparison of the stress-strain curves for the different temperatures and strain-rates of interest. A discussion of how the results can be used in the typical hydrocodes of interest will be included.

carbon/carbon↗

DOE OSTI2024

Achieving a near-ideal silicon crystal neutron interferometer using submicrometer fabrication techniques

Perfect-crystal neutron interferometry, which is analogous to Mach-Zehnder interferometry, uses Bragg diffraction to form interfering neutron paths. The measured phase shifts can be used to probe many types of interactions whether it be nuclear, electromagnetic, gravitational, or topological in nature. For a perfect-crystal interferometer to preserve coherence, the crystal must possess a high degree of dimensional tolerance as well as being relatively defect-free with minimal internal stresses. In the past, perfect-crystal neutron interferometers have been produced by a two-step process. First, a resin diamond wheel would be used to remove excess material and shape the interferometer. Afterword, the crystal would be etched to remove surface defects and elevate strains. This process has had limitations in terms of repeatability and in maximizing the final contrast, or fringe visibility, of the interferometer. We have tested various fabrication and post-fabrication techniques on a single perfect-crystal neutron interferometer and measured the interferometer's performance at each step. Here we report a robust, nonetching fabrication process with high final contrast. For the interferometer used in this work, we achieved contrasts of greater than 90% several times and ultimately finished with an interferometer that has 92% contrast and a uniform phase distribution. Published by the American Physical Society 2024

Huber, M. G. (ORCID:0000000237958445)↗

NASA NTRS1986

High temperature monotonic and cyclic deformation in a directionally solidified nickel-base superalloy

Directionally solidified (DS) MAR-M246+Hf was tested in tension and fatigue, at temperatures from 20 C to 1093 C. Tests were performed on (001) oriented specimens at strain rates of 50 % and 0.5 % per minute. In tension, the yield strength was constant up to 704 C, above which the strength dropped off rapidly. A strong dependence of strength on strain rate was seen at the higher temperatures. The deformation mode was observed to change from heterogeneous to homogeneous with increasing temperature. Low Cycle Fatigue tests were done using a fully reversed waveform and total strain control. For a given plastic strain range, lives increased with increasing temperature. For a given temperature strain rate had a strong effect on life. At 704 C, decreasing strain rates decreased life, while at the higher temperatures, decreasing strain rates increased life, for a given plastic strain range. These results could be explained through considerations of the deformation modes and stress levels. At the higher temperatures, marked coarsening caused beneficial stress reductions, but oxidation limited the life. The longitudinal grain boundaries were found to influence slip behavior. The degree of secondary slip adjacent to the boundaries was found to be related to the degree of misorientation between the grains.

Huron, Eric S.↗

NASA NTRS2008

Effect of Upper-Cycle Temperature on the Load-Biased, Strain-Temperature Response of NiTi

Over the past decade, interest in shape memory alloy based actuators has increased as the primary benefits of these solid-state devices have become more apparent. However, much is still unknown about the characteristic behavior of these materials when used in actuator applications. Recently we have shown that the maximum temperature reached during thermal cycling under isobaric conditions could significantly affect the observed mechanical response of NiTi (55 wt% Ni), especially the amount of transformation strain available for actuation and thus work output. This investigation extends that original work to ascertain whether further increases in the upper-cycle temperature would produce additional improvement in the work output of the material, which has a stress-free Af of 113 oC, and to determine the optimum cyclic conditions. Thus, isobaric, thermal-cycle experiments were conducted in the aforementioned alloy at various stress levels from 50-300 MPa using upper-cycle temperatures of 165, 200, 230, 260, 290, 320 and 350 oC. The data indicated that the amount of applied stress influenced the transformation strain available in the system, as would be expected. However, the maximum temperature reached during the thermal excursion also plays a role in determining the transformation strain, with the maximum transformation strain being developed by thermal cycling to 290 oC. In situ, neutron diffraction showed that the differences in transformation strain were related to differences in martensite texture within the microstructure when cycling to different upper-cycle temperatures. Hence, understanding this effect is important to optimizing the operation of SMA-based actuators and could lead to new methods for processing and training shape memory alloys for optimal performance.

Padula, Santo, II↗

NASA NTRS1992

Nucleation and growth of rolling contact failure of 440C bearing steel

A 'two-body' elasto-plastic finite element model of 2-dimensional rolling and rolling-plus-sliding was developed to treat the effect of surface irregularities. The model consists of a smooth cylinder in contact with a semi-infinite half-space that is either smooth or fitted with one of 0.4 microns deep or 7 microns deep groove, or a 0.4 microns high ridge-like asperity. The model incorporates elastic-linear-kinematic hardening-plastic (ELKP) and non-linear-kinematic hardening-plastic (NLKP) material constitutive relations appropriate for hardened bearing steel and the 440C grade. The calculated contact pressure distribution is Hertzian for smooth body contact, and it displays intense, stationary, pressure spikes superposed on the Hertzian pressure for contact with the grooved and ridged surface. The results obtained for the 0.4 microns deep groove compare well with those reported by Elsharkawy and Hamrock for an EHD lubricated contact. The effect of translating the counterface on the half space as opposed to indenting the half space with the counter face with no translation is studied. The stress and strain values near the surface are found to be similar for the two cases, whereas they are significantly different in the subsurface. It is seen that when tiny shoulders are introduced at the edge of the groove in the finite element model, the incremental plasticity and residual stresses are significantly higher in the vicinity of the right shoulder (rolling direction is from left to right) than at the left shoulder. This may explain the experimental observation that the spall nucleation occurs at the exit end of the artificially planted indents. Pure rolling calculations are compared with rolling + sliding calculations. For a coefficient of friction, mu = 0.1, the effect of friction is found to be small. Efforts were made to identify the material constitutive relations which best describe the deformation characteristics of the bearing steels in the initial few cycles. Elastic-linear-kinematic hardening-plastic (ELKP) material constitutive relations produce less net plastic deformation in the initial stages for a given stress, than seen in experiments. A new set of constitutive relations: non-linear-kinematic hardening-plastic (NLKP) was used. This material model produces more plasticity than the ELKP model and shows promise for treating the net distortions in the early stages. Techniques for performing experimental measurements that can be compared with the finite element calculations were devised. The measurements are being performed on 9mm-diameter, 440C steel cylindrical rolling elements in contact with 12.5 mm-diameter, 52100 steel balls in a 3-ball-rod fatigue test machine operating at 3600 RPM. Artificial, 7 microns deep, indents were inserted on the running track of the cylindrical rolling elements and profilometer measurements of these indents made, before and after the rolling. These preliminary measurements show that the indents are substantially deformed plastically in the process of rolling. The deformations of the groove calculated with the finite element model are comparable to those measured experimentally.

Gupta, V.↗

NASA NTRS1983

Strain energy release rate analysis of cyclic delamination growth in compressively loaded laminates

Delamination growth in compressively loaded composite laminates was studied analytically and experimentally. The configuration used was a laminate with an across-the-width delamination. An approximate super-position stress analysis was developed to quantify the effects of various geometric, material, and load parameters on mode 2 and mode 2 strain energy release rates G sub/1 and G sub 2, respectively. Calculated values of G sub 1 and G sub 2 were then compared with measured cyclic delamination growth rates to determine the relative importance of G sub 1 and G sub 2. High growth rates were observed only when G sub 1 was large. However, slow growth was observed even when G sub 1 was negligibly small. This growth apparently was due to a large value of G sub 2.

Whitcomb, J. D.↗

NASA NTRS1985

Dynamic fracture mechanics

Dynamic fracture and crack propagation concepts for ductile materials are reviewed. The equations for calculating dynamic stress integrity and the dynamic energy release rate in order to study dynamic crack propagation are provided. The stress intensity factor versus crack velocity relation is investigated. The uses of optical experimental techniques and finite element methods for fracture analyses are described. The fracture criteria for a rapidly propagating crack under mixed mode conditions are discussed; crack extension and fracture criteria under combined tension and shear loading are based on maximum circumferential stress or energy criteria such as strain energy density. The development and use of a Dugdale model and finite element models to represent crack and fracture dynamics are examined.

Kobayashi, A. S.↗