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NASA NTRS1985

Sawtooth segmentation and deformation processes on the southern San Andreas fault, California

Five contiguous 12-13 km fault segments form a sawtooth geometry on the southernmost San Andreas fault. The kinematic and morphologic properties of each segment depend on fault strike, despite differences of strike between segments of as little as 3 degrees. Oblique slip (transpression) of fault segments within the Indio Hills, Mecca Hills and Durmid Hill results from an inferred 8:1 ratio of dextral slip to convergence across the fault zone. Triggered slip and creep are confined almost entirely to transpressive segments of the fault. Durmid Hill has been formed in the last 28 + or - 6 ka by uplift at an average rate of 3 + or - 1 mm/a.

Bilham, R.↗

NASA NTRS1989

Thermo-viscoelastic analysis of composite materials

The thermo-viscoelastic boundary value problem for anisotropic materials is formulated and a numerical procedure is developed for the efficient analysis of stress and deformation histories in composites. The procedure is based on the finite element method and therefore it is applicable to composite laminates containing geometric discontinuities and complicated boundary conditions. Using the present formulation, the time-dependent stress and strain distributions in both notched and unnotched graphite/epoxy composites have been obtained. The effect of temperature and ply orientation on the creep and relaxation response is also studied.

Lin, Kuen Y.↗

NASA NTRS2019

Exploration of Failure and Potential Damage Markers in Ti-6Al-4V

To improve prognostics for predicting component life, coupon tests were conducted on Ti-6Al-4V to investigate the development of damage. Various test types were employed (tension, creep, stress relaxation, and fatigue) under a wide range of temperatures and loading rates to engage various amounts of time-dependent and damage behavior. Both stiffness degradation and Poisson’s ratio were monitored to see if they were useful in indicating the initiation and accumulation of damage and subsequently the onset of failure. Stiffness exhibited large decreases with increasing strain when calculated using engineering stress and strain. However, minimal stiffness change was observed when using the true-stress and true- strain values. Detailed microscopy and image analysis were performed to document the actual physical damage that occurred within the various specimens. Two types of damage were observed: shallow surface cracks and internal pores. The severity of damage was greater in the region of localized necking and diminished further away from the neck. The area fraction of pores was higher in the necked region, yet even there it did not exceed more than a few percent and, in most cases, was significantly lower. It was observed that conditions that induced more time-dependent deformation (e.g., slower strain rate testing) resulted in a larger number of pores and larger pore sizes. The pores were always found to occur in the softer β-phase. The severity of observed damage was inconsistent with the large drop in engineering stiffness, but was more aligned with stiffness changes from the true-stress and -strain values. Poisson’s ratio was monitored on every test and showed promise as a damage indicator. It was found to be more sensitive than either the ultimate tensile strength or the inception of tertiary creep. However, calculation of Poisson’s ratio was found to be more involved than expected because of anisotropy and the presence of strain gradients along the specimen at large applied strains. First, the material had a moderate texture and resulted in anisotropy of the strains. Second, the evolution of Poisson’s ratio as a function of axial strain showed strange and unexpected behaviors, which necessitated more extensive analyses of its development. This led to an investigation on the use of small versus large strain approaches and the importance of making consistent measurements; that is, axial and transverse strain measurements over the same volume of material. Additionally, finite element analysis of a tensile sample indicated that non- uniform strain occurred in the sample prior to attaining the maximum strength. This, along with the location at which transverse strain was measured, had a significant influence on the resulting values of Poisson’s ratio. Based on this, lessons learned are offered for future testing.

Ti-6Al-4V↗

NASA NTRS1992

1400 and 1500 K Compressive Creep Properties of an NiAl/AlN Composite

Compressive creep properties of an NiAl/AlN(p) composite produced by a reaction milling process were investigated at 1400 and 1500 K and at slow strain rates, to investigate the relative strength of this composite at high temperatures, and to determine if the consolidation technique affects the 1400 K creep properties. Results indicate that the stress exponent of the NiAl/AlN(p) composite was similar to that for unreinforced NiAl. However, the activation energy for the composite was found to be more than twice that measured in the unreinforced matrix. Oxidation did not affect the composite at 1400 K, but a significant attack was observed in a sample subjected to fast deformation at 1500 K.

Whittenberger, J. D.↗

DOE OSTI2022

Innovative Method for Welding in Generation 3 CSP to Enable Reliable Manufacturing of Solar Receivers to withstand Daily Cycling at Temperatures Above 700°C (Final Technical Report)

Inconel® Alloy 740H® (alloy 740H) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. Over the past ~20 years the alloy has been optimized for weldability and high-temperature stability, approved for use in different applications. Development of a supply chain combined with the advantageous properties of the alloy (high-temperature creep strength, oxidation and corrosion resistance, etc.) have resulted in the alloy being applied to new high-temperature power cycle demonstration projects, and of particular interest are applications to concentrating solar power (CSP) to enable higher-efficiency Generation 3 CSP systems and the corresponding supercritical CO 2 (sCO 2 ) power cycle components (heat exchangers, piping, etc.). The high allowable stresses of alloy 740H also make it a desirable material for current Generation 2 CSP solar power receivers to improve cyclic capability and/or reduce receiver height. Recent experiences in demonstration projects utilizing alloy 740H identified cracking issues during welding and fabrication. In this project, a detailed study was done to confirm and clarify the Stress Relaxation Cracking (SRxC) mechanism, also known as stress relief cracking or strain-age cracking (SAC), during post-weld heat-treatment (PWHT). This involved detailed microscopy and advanced characterization to understand the root cause(s) of three failures obtained from industry. Based in-part on these findings, a targeted laboratory based SRxC test method was utilized to evaluate variables such as heat-to-heat variations, strain level, PWHT temperature, and starting material condition on three heats of alloy 740H. Industrial shop welding of cold-worked plates was also conducted. The research showed the following: SRxC was confirmed as the cracking mechanism for all field failures; Stress state (from residual stresses, constraint, deformation, and local stress concentrations) was playing a significant role in field failures and laboratory testing confirmed increasing susceptibility for all heats with increasing strain levels. High levels of microstructural strain were identified at crack initiation locations, in some cases leading to local recrystallization; Precipitate free zones (PFZs) at grain boundaries were found at relaxation cracks and crack initiation locations uniquely associated with SRxC in alloy 740H. Laboratory testing reproduced this microstructural feature which had only previously been reported in long-term creep testing of weldments. Advanced nano-scale characterization confirmed the presence of a moving boundary leading to coarsening of precipitates and PFZs where damage accumulated; The research suggested heat-to-heat variations due to local chemistry and processing may influence SRxC susceptibility, but more work is needed to fully clarify these effects. To disseminate the key learnings from this research to the scientific and engineering communities and alloy 740H end users, multiple technical publications and presentations were made, an industrial alloy 740H users meeting was held, and a new industry guideline specification document which can be directly implemented by end-users of alloy 740H was produced.

14 SOLAR ENERGY↗

NASA NTRS1981

A possible dependence of tectonic strength on the age of the crust in Asia

In Asia, the intensity and style of active tectonics appears to depend on the age of the last orogenic activity. The shields have remained essentially undeformed during the India-Eurasian collision, but Paleozoic and Mesozoic orogenic belts apparently have been reactivated by this collision, with a suggestion of greater reactivation and more diffuse deformation of the younger belts. If the greater observed heat flow in regions of more recent orogenic activity reflects, at least in part, a greater heat flow from the mantle beneath the younger belts, then the temperatures in the mantle beneath the younger belts should be higher than beneath older belts and shields. Because of the strong dependence on temperature of the creep strength of minerals, particularly of olivine, the crust and mantle beneath the hotter, younger belts should be much weaker than those beneath older belts. This difference in temperature, and consequent difference in strength, may be the cause of the greater reactivation of younger belts.

Molnar, P.↗

NASA NTRS2004

The Effect of Large Melt Fraction on the Deformation Behavior of Peridotite: Implications for the Rheology of Io' Mantle

One key constraint needed for refinement of the interior geochemical and geodynamic models of Io is the viscosity of the convecting partially- molten silicate mantle. To date, laboratory studies of partially molten mantle rocks have reached melt fractions up to approx.0.12, a value much smaller than thought to be appropriate for the asthenosphere of Io where the degree of partial melting may be 0.15 0.40 or higher. Therefore, we have performed a series of high temperature, triaxial compressive creep experiments on dry synthetic peridotites in a gas medium apparatus at a confining pressure of 300 MPa and temperatures from 1473 to 1573 K in order to understand the influence of large amounts of melt (0.15 < phi < 0.40) on the rheological behavior of partially molten rocks.

Scott, T.↗

DOE OSTI2024

Report Summarizing the Mechanical Properties of a Large ODS Ferritic Alloy Ingot by Forging at High Temperatures for Future Mother Tube Production

Oxide dispersion strengthened (ODS) ferritic alloys are considered the benchmark fuel cladding and core structural material in advanced nuclear energy reactors that require high-temperature strength and creep properties and resistance to radiation damage. The ODS ferritic alloys including 14YWT are produced by mechanical alloying (MA), which is time-consuming and is associated with high manufacturing costs that are not beneficial to being used in advanced nuclear energy reactors. This report summarizes the accomplishments in FY24 in the INM program for producing an ODS ferritic alloy by high-deformation, high-temperature processing of reactive and ferritic alloy powders for advanced reactor fuel cladding applications. Following four hot forging experiments, it was concluded that several significant challenges were encountered that were difficult to overcome. These challenges were related to using high annealing temperatures for pressure assisted sintering processes to produce dense microstructures, but the high annealing temperatures result in long range diffusion of Ti through the bcc Fe lattice and react with the YIG particles that are distributed on the prior surfaces of the ferritic alloy powders. In addition, it was determined that the high deformations induced by forging at high temperatures were not very effective for fracturing the reactive YIG particles into smaller particles and distributing them into the interior of the ferritic alloy powders. Spark plasma sintering was attempted for shortening the time at high temperatures, which led to full densification but the microstructure characterization results still showed that Ti atoms diffused over long distances in the bcc Fe lattice and reacted with the YIG particles. Finally, a short 30 minute high intensity ball milling experiment was conducted on blended 14WT and YIG powders for inducing severe deformations that caused the initially spherical powders of 14WT decorated with the YIG particles on the surfaces to transform to flakes and fracturing of YIG particles into smaller particles that were incorporated into the bcc Fe lattice. Two forgings were performed with the high intensity milled powders: first annealing for 20 minutes at 850ºC followed by forging and second annealing for 20 minutes at 1,100ºC followed by forging. At 850ºC, Ti atoms are effectively immobile, thus allowing for densification albeit incomplete. The deformation by forging after annealing for 20 minutes at 1,100ºC favored dynamic recrystallization processes that led to nano-size grains with very high stored energy due to high dislocation density. The corresponding VH data showed significant hardening that correlated with estimated strengthening of ~1650 MPa. This hybrid processing approach combining high intensity ball milling of powder with annealing and forging showed the most promise for producing an oxide dispersing strengthened ferritic alloy.

36 MATERIALS SCIENCE↗

NASA NTRS1983

Energy absorption by polymer crazing

During the past thirty years, a tremendous amount of research was done on the development of crazing in polymers. The phenomenon of crazing was recognized as an unusual deformation behavior associated with a process of molecular orientation in a solid to resist failure. The craze absorbs a fairly large amount of energy during the crazing process. When a craze does occur the surrounding bulk material is usually stretched to several hundred percent of its original dimension and creates a new phase. The total energy absorbed by a craze during the crazing process in creep was calculated analytically with the help of some experimental measurements. A comparison of the energy absorption by the new phase and that by the original bulk uncrazed medium is made.

Pang, S. S.↗

NASA NTRS1987

Nonisothermal elasto-visco-plastic response of shell-type structures

A mathematical model and solution methodologies for analyzing structural response of thin, metallic shell-type structures under large transient, cyclic or static thermomechanical loads is disussed. Among the system responses, which are associated with these load conditions, are thermal buckling and creep buckling. Thus, geometric as well as material-type nonlinearities (of high order) can be anticipated and have been considered in the development of the mathematical model. Furthermore, this was accommodated in the solution procedures. A complete true ab-inito rate theory of kinematics and kinetics for continuum and curved thin structures, without any restriction on the magnitude of the strains or the deformation, was formulated. The time dependence and large strain behavior are incorporated through the introduction of the time rates of the metric and curvature in two coordinate systems, a fixed (spatial) one and a convected (material) coordinate system. The relations between the time derivative and the covariant derivatives (gradients) have been developed for curved space and motion, so that the velocity components supply the connection between the equations of motion and the time rate of change of the metric and curvature tensors.

Simitses, G. J.↗

NASA NTRS1983

Elevated temperature biaxial fatigue

Biaxial fatigue is often encountered in the complex thermo-mechanical loadings present in gas turbine engines. Engine strain histories can involve non-constant temperature, mean stress, creep, environmental effects, both isotropic and anisotropic materials and non-proportional loading. Life prediction for the general case involving all the above factors is not a practicable research project. The current research program is limited to isothermal fatigue at room temperature and 1200 F of Hastalloy-X for both proportional and non-proportional loading. An improved method for predicting the fatigue life and deformation response under biaxial cycle loading is sought.

Jordan, E. H.↗

DOE OSTI2020

Understanding the deformation mechanisms in Ni-based superalloys with using crystal plasticity finite element method

Nl-based superalloy is considered as a good candidate due to its excellent resistance to elevated temperature deformation for long term period application. Understanding the deformation and failure mechanisms of Ni-Based superalloys is very helpful for providing design guidelines for processing Ni-based superalloys. Experimental characterization indicates that the deformation mechanisms of Ni based superalloy is strongly microstructure dependent. Besides, damage transform from the void nucleation to the macro cracks by voids growth leading to the failure of the Ni-based superalloys are also showing strong microstructure sensitivity. Therefore, this work focuses on the prediction and comprehension of the deformation and void growth behavior in Ni based superalloy at different working conditions via crystal plasticity finite element modeling and simulation. Physically based crystal plasticity frameworks were developed for newly Ni- based superalloy Haynes 282. It was found that dislocation shearing through the precipitates were acting as the main contributor to the strength of Haynes 282 at room temperature and 815°C. Our analysis of the creeping behavior of Haynes 282 exhibited that resistance of general climb replaced by the resistance induced by the deposited climb dislocation density. In addition, in the study of void growth behavior, our simulation results demonstrated that as the main loading axis perpendicular to the grain boundary (GB), voids grow more slowly on tilt GBs in bicrystals than those in single and bicrystals with twist GBs. And tilt GBs would promote the void grow into irregular shape.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Determination of surfaces of constant inelastic strain rate at elevated temperature

An experimental effort to perform special exploratory multiaxial deformation tests on tubular specimens of type 316 stainless steel at 650 C (1200 F) is described. One test specimen was subjected to a time-independent torsional shear strain test history, and surfaces of constant inelastic strain rate (SCISRs) in an axial/torsional stress space were measured at various predetermined points during the test. A second specimen was subjected to a 14-week time-dependent (creep-recovery-creep periods) torsional shear stress histogram SCISRs determinations made at 17 points during the test. The tests were conducted in a high temperature, computer controlled axial/torsional test facility using high-temperature multiaxial extensometer. The effort was successful, and for the first time the existence of surfaces of constant inelastic strain rate was experimentally demonstrated.

Battiste, R. L.↗

NASA NTRS1959

Factors Affecting the Plasticity of Sodium Chloride, Lithium Fluoride, and Magnesium Oxide Single Crystals

A study was made of the relative magnitude of the effects of various factors on the ductility of single crystals of sodium chloride (NaCl), lithium fluoride (LiF), and magnesium oxide (MgO). Specimen treatments included water-polishing, varying cleavage rate, annealing, quenching, X-irradiation, surface coating, aging, and combinations of some of these treatments. The mechanical behavior of the crystals was studied in flexure and in compression, the latter study being performed at both constant strain rate and constant load. Etch-pit studies were carried out to provide some pertinent information on the results of pretreatment on the dislocation concentration and distribution in the vicinity of the surface. The load deformation curves for these ionic single crystals show an initial region of very low slope which proved to be due to anelastic deformation. The extent of initial anelastic deformation is modified by specimen pretreatment in a way that suggests that this deformation is the result of expansion of cleaved-in dislocation loops, which can contract on the removal of the stress. The effects of the various pretreatments on the load and deflection at fracture are in accord with the prediction one might make with regard to their effect on the nucleation of fatal surface cracks. For NaCl, increases in ductility are always accompanied by increases in strength. The creep constants for NaCl are a function of treatments which affect the bulk structure but are not a function of treatments which only affect the surface.

Stearns, Carl A.↗

DOE OSTI2025

Accounting for Sustainability and Performance: Contrasting Effects of PET-Derived Modifiers on Asphalt Durability

The valorization of waste plastics in roadway infrastructure requires careful balance between sustainability and performance, as ineffective modifiers may incur both environmental and financial costs. This study shows that two modifiers derived from the same waste plastic source (PET)-DOTP (N1,N4-(dioctyl)terephthalamide) and HETP (N1,N4-Bis(2-hydroxyethyl)terephthalamide)-exhibit opposite effects on asphalt properties, despite having nearly the same carbon footprint. DOTP improves elastic recovery in multiple creep recovery tests (MCRT), while HETP increases strain accumulation and reduces elasticity. Density functional theory (DFT) shows that DOTP's molecular structure can disperse well in bitumen mixtures by binding to both polar and non-polar components. In contrast, HETP binds only to the binder's polar sites, lacking adequate dispersion. This increases the risk of aggregation of polar compounds in the bitumen mixture, resulting in a more deformation-prone binder. A techno-economic analysis highlights trade-offs between sustainability and performance in industrial-scale synthesis. This study advocates for applying first-principles thinking in material design, coupled with experimental validation, to engineer plastic waste-derived additives that achieve both performance and sustainability goals.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Design and Scoping Tests on Alloy 617 Using Notched Specimen Geometry to Validate Methods for Multiaxial Stress Relaxation

In FY 2022, a development effort was initiated at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) to examine the multiaxial stress-relaxation behavior and multiaxial stress-state effect on the creep-fatigue (CF) performance for Alloy 617 at elevated temperatures. This effort supported the development of the design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5. In this work, two types of the notch specimen geometries were designed. An inelastic constitutive model was used to investigate the stress triaxiality and elastic follow-up effects on the notch specimens under CF deformation in the finite element (FE) simulations. The numerical study demonstrated that the stress triaxiality and elastic follow-up caused by the notches both play significant roles in the stress-relaxation behavior. In addition, Alloy 617 CF experiments were designed, and the testing on the notch specimens is ongoing. CF test failure data will be generated on the specimens with notches under various conditions in FY 2023, and the results will be used to validate methods for accounting for the multiaxial stress relaxation effect in the design code.

36 MATERIALS SCIENCE↗

NASA NTRS2003

Crustal Deformation in Southcentral Alaska: The 1964 Prince William Sound Earthquake Subduction Zone

This article, for Advances in Geophysics, is a summary of crustal deformation studies in southcentral Alaska. In 1964, southcentral Alaska was struck by the largest earthquake (moment magnitude 9.2) occurring in historical times in North America and the second largest earthquake occurring in the world during the past century. Conventional and space-based geodetic measurements have revealed a complex temporal-spatial pattern of crustal movement. Numerical models suggest that ongoing convergence between the North America and Pacific Plates, viscoelastic rebound, aseismic creep along the tectonic plate interface, and variable plate coupling all play important roles in controlling both the surface and subsurface movements. The geodetic data sets include tide-gauge observations that in some cases provide records back to the decades preceding the earthquake, leveling data that span a few decades around the earthquake, VLBI data from the late 1980s, and GPS data since the mid-1990s. Geologic data provide additional estimates of vertical movements and a chronology of large seismic events. Some of the important features that are revealed by the ensemble of studies that are reviewed in this paper include: (1) Crustal uplift in the region that subsided by up 2 m at the time of the earthquake is as much as 1 m since the earthquake. In the Turnagain Arm and Kenai Peninsula regions of southcentral Alaska, uplift rates in the immediate aftermath of the earthquake reached 150 mm/yr , but this rapid uplift decayed rapidly after the first few years following the earthquake. (2) At some other locales, notably those away the middle of the coseismic rupture zone, postseismic uplift rates were initially slower but the rates decay over a longer time interval. At Kodiak Island, for example, the uplift rates have been decreasing at a rate of about 7mm/yr per decade. At yet other locations, the uplift rates have shown little time dependence so far, but are thought not to be sustainable throughout the several hundred year recurrence time for great earthquake. The nearly 10 mm/yr uplift rate at Seldovia on the Kenai Peninsula is an example.

Cohen, Steven C.↗

DOE OSTI2025

Microstructure-Based Understanding of High-Temperature Deformation Behaviors in Laser Powder Bed Fusion (LPBF) 316H Stainless Steel

This report presents the results of high-temperature mechanical property testing and microstructural analysis of laser powder bed fusion (LPBF) 316H stainless steel (SS) conducted during Fiscal Year 2025 (FY25) under the U.S. Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program. The study builds upon prior work by expanding the mechanical property test matrix and advancing a microstructure-based mechanistic understanding of LPBF 316H SS performance, with a focus on the solution annealed (SA, 1100°C for 1 hour) materials. High-temperature tension, creep, fatigue, and creep-fatigue tests were performed. Thermal aging studies were conducted. Advanced characterization techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and high-energy synchrotron X-ray diffraction, were employed to investigate the microstructural evolution during thermal aging and mechanical testing. It was discovered that the as-built (AB) LPBF 316H SS exhibited precipitation kinetics during thermal aging that are 10–100 times faster than its wrought counterpart due to the presence of high densities of preferred nucleation sites, while the precipitation kinetics in SA LPBF 316H was under investigation. The accelerated precipitation of embrittling phases such as sigma phase in LPBF 316H SS compared to its wrought counterpart led to significant impacts on creep ductility. The influence of laser printing parameters and build orientations on fatigue and creep-fatigue performance was observed. In assessing the creep-fatigue performance, it was discovered that the SA LPBF 316H samples failed in less than 200 cycles under 595°C, 0.5% (strain amplitude) with a 60-minute hold time. This work establishes a mechanistic framework for predicting the long-term behavior of LPBF 316H SS, supporting its rapid qualification under the ASME BPVC. The findings contribute to the broader goal of enabling the deployment of advanced materials in next-generation nuclear energy systems. An outlook for FY26 work, including continued aging studies, mechanical testing, and microstructural characterization, is provided.

36 MATERIALS SCIENCE↗