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Results for “RESIDUAL STRESSES”

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DOE OSTI2015

Nonlinear parallel momentum transport in strong electrostatic turbulence

Most existing theoretical studies of momentum transport focus on calculating the Reynolds stress based on quasilinear theory, without considering the nonlinear momentum flux-〈v{sup ~}{sub r}n{sup ~}u{sup ~}{sub ∥}〉. However, a recent experiment on TORPEX found that the nonlinear toroidal momentum flux induced by blobs makes a significant contribution as compared to the Reynolds stress [Labit et al., Phys. Plasmas 18, 032308 (2011)]. In this work, the nonlinear parallel momentum flux in strong electrostatic turbulence is calculated by using a three dimensional Hasegawa-Mima equation, which is relevant for tokamak edge turbulence. It is shown that the nonlinear diffusivity is smaller than the quasilinear diffusivity from Reynolds stress. However, the leading order nonlinear residual stress can be comparable to the quasilinear residual stress, and so may be important to intrinsic rotation in tokamak edge plasmas. A key difference from the quasilinear residual stress is that parallel fluctuation spectrum asymmetry is not required for nonlinear residual stress.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Stress characterization for friction-stir-welded electric vehicle battery trays with application of neutron diffraction

The battery tray is an essential component that protects and controls battery-cell temperatures in electric and plug-in hybrid vehicles. The functional stress limit of the battery tray heavily depends on the residual stress acquired from the manufacturing process. Consequently, exceeding the stress limit of the battery tray during operation could compromise the battery-cell banks and may risk the vehicle's safety. Hence, understanding residual stress formation is vital for design and safety concerns. Here, in the current study, AA 6061-plates were friction stir welded to an A365 high-pressure die-cast battery tray to create sealed coolant channels in the battery tray. However, this multi-material lap friction stir weld introduces residual stress into the battery tray, resulting in distortion. This distortion was mitigated using burnishing or coining operations, though straightening the battery tray had initially unknown effects on the residual stress. Therefore, neutron diffraction was utilized to characterize residual stresses after straightening. The results indicate that the friction stir welding (FSW) operation generated residual stresses exceeding the yield strength of the material, consequently deforming the battery tray by ±3 mm from the pre-weld geometry. The burnishing operation reduced the residual stresses below the material's yield strength while restoring the tray to within ±0.75 mm of the pre-weld geometry. Similarly, the coining operation restored the battery tray to within ±0.75 mm of the pre-weld geometry, however, increasing the number of locations where the residual stress exceeds the yield strength of the material.

36 MATERIALS SCIENCE↗

NASA NTRS1975

Residual thermal stresses in a solid sphere cast from a thermosetting material

Expressions are developed for the residual thermal stresses in a solid sphere cast from a chemically hardening thermosetting material in a rigid spherical mold. The description of the heat generation rate and temperature variation is derived from a first-order chemical reaction. Solidification is described by the continuous transformation of the material from an inviscid liquidlike state into an elastic solid, with intermediate properties determined by the degree of chemical reaction. Residual stress components are obtained as functions of the parameters of the hardening process and the properties of the hardening material. Variation of the residual stresses with a nondimensionalized reaction rate parameter and the relative compressibility of the hardened material is discussed in detail.

Levitsky, M.↗

DOE OSTI2015

THE EFFECTS OF FABRICATION INDUCED RESIDUAL STRESS-STRAIN STATES ON THE IRRADIATION PERFORMANCE OF MONOLITHIC MINI-PLATES

This article evaluates the initial stress-strain state of the monolithic fuel plates and their effects on the overall irradiation performance. The monolithic fuel is a proposed fuel form for high-performance research reactors to achieve higher uranium densities within the core to allow the use of low-enriched uranium fuel. These plate-type fuels consist of a high density low enrichment Uranium-Molybdenum alloy based fuel, a diffusion barrier made of Zirconium, and a cladding made of Aluminum. Because the fabrication of monolithic plates involves multiple stages and the foil material is subjected to various thermo-mechanical processes, a presence of significant stress-strain fields is likely. In addition, the choice of the fabrication process may also cause variations in the foil’s microstructure. There are interests if the overall irradiation performance could be affected by the different initial stress-strain state and the microstructural characteristics. To investigate these concerns, a representative plate was simulated for various initial stress-strain states. First, the co-rolling process for thickness reduction stage of the foil was simulated. For this, a scaled version of the process was evaluated to identify distinct stress profiles on the selected paths. These profiles were then used to define an initial state for the foil before Hot Isostatic Pressing. Additional HIP simulations were also performed to study the cases with stress-free foils prior HIP bonding. The purpose of these simulations was to mimic the stress relief treatment after co-rolling, which aims to remove the residual stresses and minimize the material anisotropy. For the HIP process with initially stress-free foil, several bonding temperatures were considered, including the nominal bonding temperature. The final case considered a plate without initial stresses and strains, assuming a hypothetical case in which the plate would be subjected to a post-fabrication heat treatment to relieve the process-induced stresses before irradiation. Finally, the irradiation processes were simulated for all the cases with distinct pre-irradiation stress-strain profiles. For all cases, the same irradiation parameters were used. The resulting distortions, stress-strain fields and temperature profiles were gathered on selected locations. Finally, a comparative evaluation was made to determine the sensitivity to the pre-irradiation stress-strain variations. The irradiation simulations have revealed that fabrication induced stresses in fuel would be relieved quickly due to large irradiation creep strain. The results indicated that the stress-strain behavior of the fuel foil is not affected significantly by the fabrication process. It is important to note that this excludes microstructural characteristics, which may have important implications on overall behavior. In the cladding however, the stresses continue increase and additional plastic strains are generated. This is due to irradiation hardening by fast neutrons. Additional stresses and strains are formed in the cladding as a result of displacements caused by the volumetric swelling of the fuel foil.

42 ENGINEERING↗

DOE OSTI2016

Second order kinetic theory of parallel momentum transport in collisionless drift wave turbulence

A second order kinetic model for turbulent ion parallel momentum transport is presented. A new nonresonant second order parallel momentum flux term is calculated. The resonant component of the ion parallel electrostatic force is the momentum source, while the nonresonant component of the ion parallel electrostatic force compensates for that of the nonresonant second order parallel momentum flux. The resonant component of the kinetic momentum flux can be divided into three parts, including the pinch term, the diffusive term, and the residual stress. By reassembling the pinch term and the residual stress, the residual stress can be considered as a pinch term of parallel wave-particle resonant velocity, and, therefore, may be called as “resonant velocity pinch” term. Considering the resonant component of the ion parallel electrostatic force is the transfer rate between resonant ions and waves (or, equivalently, nonresonant ions), a conservation equation of the parallel momentum of resonant ions and waves is obtained.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2008

Elastic-Plastic Fracture Mechanics Analysis of Critical Flaw Size in ARES I-X Flange-to-Skin Welds

NASA's Ares 1 Upper Stage Simulator (USS) is being fabricated from welded A516 steel. In order to insure the structural integrity of these welds it is of interest to calculate the critical initial flaw size (CIFS) to establish rational inspection requirements. The CIFS is in turn dependent on the critical final flaw size (CFS), as well as fatigue flaw growth resulting from transportation, handling and service-induced loading. These calculations were made using linear elastic fracture mechanics (LEFM), which are thought to be conservative because they are based on a lower bound, so called elastic, fracture toughness determined from tests that displayed significant plasticity. Nevertheless, there was still concern that the yield magnitude stresses generated in the flange-to-skin weld by the combination of axial stresses due to axial forces, fit-up stresses, and weld residual stresses, could give rise to significant flaw-tip plasticity, which might render the LEFM results to be non-conservative. The objective of the present study was to employ Elastic Plastic Fracture Mechanics (EPFM) to determine CFS values, and then compare these values to CFS values evaluated using LEFM. CFS values were calculated for twelve cases involving surface and embedded flaws, EPFM analyses with and without plastic shakedown of the stresses, LEFM analyses, and various welding residual stress distributions. For the cases examined, the computed CFS values based on elastic analyses were the smallest in all instances where the failures were predicted to be controlled by the fracture toughness. However, in certain cases, the CFS values predicted by the elastic-plastic analyses were smaller than those predicted by the elastic analyses; in these cases the failure criteria were determined by a breakdown in stress intensity factor validity limits for deep flaws (a greater than 0.90t), rather than by the fracture toughness. Plastic relaxation of stresses accompanying shakedown always increases the calculated CFS values compared to the CFS values determined without shakedown. Thus, it is conservative to ignore shakedown effects.

Chell, G. Graham↗

DOE OSTI2013

Novel dense membrane for hydrogen separation for energy applications

The main objectives of this project are: (1) Characterization of the thermo mechanical properties of the novel dense HTM bulk sample; (2) Development of a correlation among the intrinsic factors (such as grain size and phase distribution), and the extrinsic factors (such as temperature and atmosphere) and the thermo-mechanical properties (such as strengths and stress) to predict the performance of a HTM system (HTM membrane and porous substrate) ; and (3) Evaluation of the stability of the novel HTM membrane and its property correlations after thermal cycling. Based on all results and analysis of the thermo mechanical properties for the HTM cermet bulk samples, several important conclusions were made. The mean σfs at room temperature is approximately 356 MPa for the HTM cermet. The mean σfs value decreases to 284 MPa as the temperature increases to 850?C. The Difference difference in atmosphere, such as air or N2, had an insignificant effect on the flexural strength values at 850?C for the HTM cermet. The HTM cermet samples at room temperature and at 500?C fractured without any significant plastic deformation. Whereas, at 850?C, the HTM cermet samples fractured, preceded by an extensive plastic deformation. It seems that the HTM cermet behaves more like an elastic material such as a nonmetal ceramic at the room temperature, and more like a ductile material at increased temperature (850?C). The exothermic peak during the TG/DTA tests centered at 600?C is most likely associated with both the enthalpy change of transformation from the amorphous phase into crystalline zirconia and the oxidation of Pd phase in HTM cermet in air. The endothermic peak centered at 800?C is associated with the dissociation of PdO to Pd for the HTM cermet sample in both inert N2 environment and air. There is a corresponding weight gain as oxidation occurs for palladium (Pd) phase to form palladium oxide (PdO) and there is a weight loss as the unstable PdO is dissociated back to Pd and oxygen. The normal stress and shear stresses from the Mohr?s circle indicate that the residual stress in the HTM cermet sample is mainly as compressive residual stress in the magnitude of -135 to -155 MP, and with very little shear stress (in the magnitude of 10 MPa). The magnitude of change in the normal stress and the shear stress is insignificant in the HTM after 120 thermal cycles. However, the principle normal stress changes from compressive to tensile residual stress and there is a significant increase in the shear stress after 500 thermal cycles. The calculated value based on the equation and the Mohr?s circle is found to be consistent with the experimental value for the as-received HTM cermet samples. At some rotation (φ) angle, the residual stress was found to be as tensile stress. Most ceramic material is weak in tension, and develops microscopic cracks. With treatment of 120 thermal cycles between 50?850?C, the HTM- sample exhibited thermally-induced cracks on the surface. Visually observable cracks appeared on the surface of HTM cermet with continuous thermal cycling, after 500 thermal cycles. The XRD powder diffraction analysis indicated an increased amount of crystalline PdO crystalline in HTM cermet after 120 and 500 thermal cycles as compare to the as-received samples. The Pd crystalline peaks were found to significantly decrease in peak intensity with thermal cycling. Higher peak intensity for PdO phase was observed with increased number of thermal cycles. A Monoclinic monoclinic zirconia phase was first identified in the as-received HTM as-received sample. However, with thermal cycling treatment of both 120 and 500 thermal cycles, the M-ZrO2 phase is transformed to the tetragonal YSZ, which is consistent with the thermal analysis results by TG/DTA. Correlations of the microstructural and thermo-mechanical properties of both selected reference material and ANL-3e HTM cermet bulk sample are affected mainly by porosity and microstructural features, such as grain size and pore size/distribution. The Young?s Modulus (E-value), especially, is positively proportional to the flexural strength for materials with similar crystallographic structure. For different crystallographic materials, physical properties such as E and density are independent of mechanical properties, such as flexural strength.. Microstructural properties, particularly, grain size and crystallographic structure, and thermodynamic properties are the main factors affecting the mechanical properties at both room and high temperatures. The oxidation and the plasticity of Pd phase mainly affect the mechanical properties of HTM cermet at high temperature or with thermal cycling treatment. Changes in the residual stress and microstructure affect the mechanical properties of HTM when subjected to high temperature or thermal cycling treatment.

08 HYDROGEN↗

DOE OSTI2022

The effect of stress on the migration of He gas bubbles under a thermal gradient in Fe by phase-field modeling

Here a phase-field model is parameterized to study the effect of elastic stresses on the migration of He gas bubbles in Fe under a temperature gradient. Stresses caused by the gas bubble pressure and residual stress in the Fe matrix are considered. The dependence of He bubble migration velocity on the magnitude of the residual stress, average temperature, temperature gradient, and bubble size is measured. In agreement with a theoretical model based on surface diffusion, simulation results demonstrate that He bubbles move towards the high temperature region with velocities in Fe that are orders of magnitude faster than previously reported in UO 2 . It is found that local stresses in the matrix caused by the He bubble have negligible effect on the bubble migration process; however, residual stresses in the Fe matrix, potentially caused by processing or irradiation, can modestly modify bubble kinetics through pressure dependence of the He diffusion coefficients. Compressive residual stress decreases diffusion coefficients for bulk and surface diffusion mechanisms, thus reducing the migration velocity of the gas bubble. In contrast, tensile residual stress increases the diffusion coefficients, resulting in an increase in the gas bubble migration velocity. This pressure dependence is also consistent with a theoretical model. This phase field model lays the foundation for analysis of bubble coalescence-induced fracture in He bubble-containing steels.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Mono-textured nanocrystalline thin films with pronounced stress-gradients: On the role of grain boundaries in the stress evolution

The origins of residual stress gradients in nanocrystalline thin films, especially the role of grain size and texture gradients, are still not fully understood. In this work, the stress evolution in exemplary nanocrystalline TiN thin films with one and two fiber texture components as well as in homogeneous amorphous SiO{sub x} films is analyzed using wafer curvature as well as laboratory and synchrotron cross-sectional nanobeam X-ray diffraction techniques. The stress evolution across the film thickness is attributed to the evolutionary nature of microstructural development at the individual growth stages. While the effect of the smooth crystallographic texture changes during growth is only of minor importance, as this does not significantly affect the dominant stress formation mechanisms, the change in the grain size accompanied by a change of the volume fraction of grain boundaries plays a decisive role in the stress development across the film thickness. This is demonstrated on the monotextured thin films, where the residual stresses scale with the apparent grain size. These findings are validated also by the investigations of stress profiles in homogeneous amorphous SiO{sub x} films exhibiting no grain boundaries.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1993

Internal strain analysis of ceramics using scanning laser acoustic microscopy

Quantitative studies of material behavior characteristics are essential for predicting the functionality of a material under its operating conditions. A nonintrusive methodology for measuring the in situ strain of small dimeter (to 11 microns) ceramic fibers under uniaxial tensile loading and the local internal strains of ceramics and ceramic composites under flexural loading is introduced. The strain measurements and experimentally observed mechanical behavior are analyzed in terms of the microstructural development and fracture behavior of each test specimen evaluated. Measurement and analysis of Nicalon silicon carbide (SiC) fiber (15 microns diameter) indicate that the mean elastic modulus of the individual fiber is 185.3 GPa. Deviations observed in the experimentally determined elastic modulus values between specimens were attributed to microstructural variations which occur during processing. Corresponding variations in the fracture surface morphology were also observed. The observed local mechanical behavior of a lithium alumino-silicate (LAS) glass ceramic, a LAS/SiC monofilament composite, and a calcium alumino-silicate (CAS)/SiC fully reinforced composite exhibits nonlinearities and apparent hysteresis due to the subcritical mechanical loading. Local hysteresis in the LAS matrices coincided with the occurrence of multiple fracture initiation sites, localized microcracking, and secondary cracking. The observed microcracking phenomenon was attributed to stress relaxation of residual stresses developed during processing, and local interaction of the crack front with the microstructure. The relaxation strain and stress predicted on apparent mechanical hysteresis effects were defined and correlated with the magnitude of the measured fracture stress for each specimen studied. This quantitative correlation indicated a repeatable measure of the stress at which matrix microcracking occurred for stress relief of each material system. Stress relaxation occurred prior to the onset of steady state cracking conditions. The relaxation stress occurred at 18.5 percent of the fracture stress in LAS and 11.0 percent of the yield stress in CAS/SiC. The relaxation stress ratio was dependent upon the dominant fracture mode of the LAS/SiC specimens. Relaxation stress ratios greater than 0.30 were observed for specimens which fractured due to shear at the fiber matrix interface; specimens which fracture due to tensile cracking had relaxation stress ratios less than 0.30. The stress relaxation ratio appeared to be a specific characteristic of the glass ceramic material. The measured stress relaxation for LAS indicated a measure of the inherent residual stresses in the material due to processing and suggested localized toughening mechanisms for brittle material structures.

Kent, Renee M.↗

DOE OSTI2022

Interlaboratory Reproducibility of Contour Method Data in a High Strength Aluminum Alloy

The contour method for residual stress measurement has seen significant development, but an experimental reproducibility study utilizing physical samples has not been published. A double-blind reproducibly study is reported, having scope beginning with EDM cutting and ending with residual stress calculation. A reinforced I-beam sample geometry is identified for its unique residual stress profile when extracted from residual stress bearing quenched aluminum bar (7050-T74). Contour measurements are prescribed on a midplane of symmetry with dimensions 24.0 mm by 50.0 mm. Fourteen identically prepared samples are fabricated from a single long bar with well characterized and uniform residual stress. Five samples throughout the bar are identified for planning measurements to validate sample uniformity and overall suitability of the residual stress field. The planning measurements employ a range of techniques: contour method, neutron diffraction, and hole-drilling. Eight samples are distributed to an international group of participants to execute their standard measurement practice. A double-blind process is followed to provide anonymity. Results are provided by eight participants: six being self-similar and two being quite different, the latter set aside as outliers. An average residual stress field is established from non-outlying results and the spatial distribution of reproducibility standard deviation is determined. The average stress field ranges from -60 to 70 MPa and the reproducibility standard deviation averages 8.1 MPa on the measurement plane. The average reproducibility standard deviation is about 3 × larger for points within 1.0 mm of plane boundaries (17.6 MPa) than for the remaining points (6.1 MPa). Reproducibility standard deviation (among different labs) for contour method residual stress measurement is found to be very similar to repeatability standard deviation (in a single lab) reported in prior work. The reproducibility observed here, for the entire measurement process, is also similar to that found in a prior reproducibility study limited to contour method data analysis.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Seshadri, Banavara R.↗

DOE OSTI2018

Complete Status Report Documenting the Development of Friction Stir Welding for Producing a Butt Joint in Thin Wall Tubing of ODS Alloys

A challenging attempt using friction stir welding to produce a butt joint between two 1.0 mm thick plates of 14YWT was nearly successful. The modified tool pin mostly penetrated the thickness of the adjoined thin plate samples resulting in a small blunt notch on the bottom surface of the butt joint. A bend occurred in the thin plate sample due to formation of stresses from clamping the thin plate sample during FSW. The peak displacement of the bend occurred along the center line of the butt joint. The weld zone showed good microstructure mixing with some flashing mostly on the retreating side that suggested excess heat input by friction between the traveling and spinning tool pin and thin plates of 14YWT. Neutron diffraction experiments were performed on the bent sample of 14YWT to measure the residual stresses in the butt joint on the HB-2B beam line at the Neutron Residual Stress Facility at HFIR. However, the neutron scattering to background noise ratio was very low during data acquisition. Measurements of lattice strains were obtained in the rolling (RD) and normal (ND) directions but not in the extrusion direction (ED) of the thin plate sample. Unfortunately, the quality of the data was not sufficient for determining the residual stresses in the butt joint. From the previous neutron scattering experiments conducted on four hot rolled plates (R1, R2, R3 and R4) of 14YWT, the residual stresses were calculated from lattice strain data and plotted in 2-D color contour maps for ED, RD and ND. The results showed variations in the magnitude and spatial position of residual stresses in the microstructure of the four plates. The magnitude in residual stresses in ED and RD increased gradually with increasing rolling deformation for R1 (50%) to R2 (76%), followed by larger increases in R3 (89%) and R4 (95%). The maximum peaks in residual stresses for R4 was ~710-730 MPa in ED and RD. The residual stresses in ND were below ~300 MPa for each of the 4 rolled plates, with a maximum residual stress in R4 (95%) of ~400 MPa. These results indicated that significant residual stresses representing ~57% of the yield stress of 14YWT (SM13) had accumulated in the 14YWT plate after hot rolling to the 1 mm thickness, which was used in the FSW experiments. The microstructure analysis of the 1.0 mm thick plate of 14YWT containing the butt joint produced by FSW revealed significant changes in the grain structure and texture between the unaffected zone (UZ) of the rolled plate and the butt joint weld. In the UZ, the grains were severely elongated after 95% deformation and mainly possessed the {101} texture component in the ED. Two predominant grain misorientation angles were observed: one consisting of small misorientations of <5º between highly elongated grains and the other consisting of large misorientations of >15º in pockets of small grains that might have formed by dynamic recrystallization processes during rolling of the plate at 1000ºC. The morphology and texture of grains in the heat affected zone (HAZ) were similar to those in UZ, except the grains had coarsened due to excess heat input during FSZ. A population of pores formed and the grains both coarsened and changed to isotropic morphology in the microstructure of the butt joint on both the advancing and retreating sides. The texture of grains in both regions were randomly orientated between the 3 poles {001}, {101} and {111}. The main difference in texture of grains between the advancing side and retreating side was with the misorientation angles of neighboring grains. Most of the grains in the advancing side had misorientation angles of >5º indicating that these grains experienced recrystallization. On the retreating side, areas containing larger grains showed high misorientation angles of >15º compared to areas appearing as bands of grains with misorientation angles of <5º and between 5º-15º. Numerous small pockets of grains with low misorientation angles of <5º were distributed in the microstructure among the grains showing high misorientation angles of >15º. It was determined that the grains associated with low misorientation angles contained sub-grain structures, which was consistent with both recrystallization and recovery mechanisms for grains located on the retreating side of the butt joint. These results demonstrate the complex microstructure that evolves in the microstructure of 14YWT resulting from the input of high temperatures and severe deformations during FSW.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Cold rolling can be used in-process or post-process to improve microstructure, mechanical properties and residual stress in directed-energy-deposition techniques, such as the high deposition rate wire + arc additive manufacturing (WAAM) process. Finite element simulations of the rolling process are employed to investigate the effect of rolling parameters, in particular rolling load and roller profile radius on the residual stress field as well as plastic strain distribution for the profiled roller. The results show the response to rolling of commonly used structural metals in WAAM, i.e., AA2319, S335JR steel and Ti-6Al-4V, taking into account the presence of residual stresses. The rolling load leads to changes in the location and the maximum value of the compressive residual stresses, as well as the depth of the compressive residual stresses. However, the roller profile radius only changes the maximum value of these compressive residual stresses. Changing the rolling load influences the equivalent plastic strain close to the top surface of the wall as well as in deeper areas, whereas the influence of the roller profile radius is negligible. The plastic strain distribution is virtually unaffected by the initial residual stresses prior to rolling. Finally, design curves were generated from the simulations for different materials, suggesting ideal rolling load and roller profile combinations for microstructural improvement requiring certain plastic strains at a specific depth of the additive structure.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Complete Status Report Documenting Weld Development for Thin Wall Tubing of ODS Ferritic Alloys

Beginning in 2015, research in the FCRD program began the development of FSW for joining thin sections of 14YWT in the form of thin (0.5 mm) plate and ultimately thin wall tubing. In the previous fiscal year, a ~1 mm thick plate, or sheet, of 14YWT was produced by hot rolling with no edge cracking. The initial FSW experiment was performed on the 1 mm thick plate and involved a bead-on-plate weld in which the spinning pin tool is plunged into the plate surface, but does not penetrate the thickness of the plate, and then travels the length of the plate. The FSW run successfully produced a bead-on-plate stir zone on the 1 mm thick plate of 14YWT, but no characterization studies of the stir zone were performed by the end of FY15. Therefore, the results presented in this report cover the microstructural analysis of the bead-on-plate stir zone and the initial research task on obtaining tensile properties of the stir zone using the digital image correlation (DIC) approach during testing of miniature tensile specimens to assess the quality of the FSW parameters used in the initial experiment. The results of the microstructural characterization study using optical, scanning electron and scanning transmission electron microscopies showed the grain structure in the SZ to have isotropic and irregular shape but very similar size compared to the highly elongated grains oriented horizontally with the plane of the plate that were observed in the unaffected zone of 14YWT. Several cracks oriented horizontally were observed mostly on the retreating side of the SZ in both the SZ and TMAZ. These cracks may have formed due to insufficient pressure being exerted on the top surface of the plate by the shoulder and pin tool during the FSW run. High resolution STEM-EDS analysis showed the presence of the Y-Ti-O particles in the SZ, but that some particles exhibited coarsening. Overall, the FSW parameters used to produce the bead-on-plate SZ in the 0.1 cm thick plate of 14YWT were nearly optimized. The results of the digital image correlation (DIC) analysis of the two SS-Mini-2 tensile specimens fabricated from the 0.1 cm thick plate of 14YWT showed that the specimens exhibited high strength and good ductility. However, strain localization occurred in one of the specimens during the tensile test that was too close to the grips, which invalidated the data from the DIC analysis. This was surprising since the abrupt crack pop-in that occurred in the 0.1 cm thick plate of 14YWT during fabrication by wire EDM suggested that residual stresses were high. Residual stress measurements and the effects of post weld heat treatment on the FSW quality of joined 14YWT plates will be investigated in the next FW work package.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗

DOE OSTI2024

Intrinsic Toroidal Rotation Driven by Turbulent and Neoclassical Processes in Tokamak Plasmas from Global Gyrokinetic Simulations

Gyrokinetic tokamak plasmas can exhibit intrinsic toroidal rotation driven by the residual stress. While most studies have attributed the residual stress to the parallel-momentum flux from the turbulent E × B motion, the parallel-momentum flux from the drift-orbit motion (denoted $Π^D_\parallel$) and the E × B-momentum flux from the E × B motion (denoted $Π_{E×B}$) are often neglected. Here, we use the global total-f gyrokinetic code XGC to study the residual stress in the core and the edge of a DIII-D H-mode plasma. Numerical results show that both $Π^D_\parallel$ and $Π_{E×B}$ make up a significant portion of the residual stress. In particular, $Π^D_\parallel$ in the core is higher than the collisional neoclassical level in the presence of turbulence, while in the edge it represents an outflux of countercurrent momentum even without turbulence. Using a recently developed “orbit-flux” formulation, we show that the higher-than-neoclassical-level $Π^D_\parallel$ in the core is driven by turbulence, while the outflux of countercurrent momentum from the edge is mainly due to collisional ion orbit loss. In conclusion, these results suggest that $Π^D_\parallel$ and $Π_{E×B}$ can be important for the study of intrinsic toroidal rotation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Validation Data for Benchmarking Wire Arc Additive Manufacturing Process Simulations

Residual stresses cause geometric distortion and affect mechanical performance of additively manufactured structures, yet they are notoriously difficult to assess and predict. Distortion (warpage) can drive parts outside dimensional tolerance limits, leading to part rejection or rework. For parts that meet tolerance, locked-in residual stress fields can affect structural integrity during operation, particularly subcritical cracking by fatigue, creep, or corrosion. This work develops benchmark data for a common additive manufacturing process (Wire Arc Additive Manufacturing) that can be applied for calibration and validation of physical process models that predict residual stress fields. The work includes design of two different samples of differing geometry, detailed manufacturing records for a set of physical samples, and an extensive set of residual stress measurement data developed using two diverse techniques (the contour method and neutron diffraction). An initial application of the work is also reported, where a modeling challenge was issued to secure residual stress model predictions from two independent laboratories that were blind to residual stress measurement data. These initial blind residual stress predictions show significant discrepancies relative to the measurement data, illustrating the potential value of the underlying validation data. An open repository for this work, including the sample designs, manufacturing process records, and the residual stress data, is also provided for future application in non-blind validation efforts.

36 MATERIALS SCIENCE↗