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NASA NTRS1981

Effects of environmental variables on the crack initiation stages of corrosion fatigue of high strength aluminum alloys

Fatigue initiation in six aluminum alloys used in the aircraft industry was investigated. Cyclic loading superimposed on a constant stress was alternated with atmospheric corrosion. Tests made at different stress levels revealed that a residual stress as low as 39% of the yield strength caused stress corrosion cracking in some of the alloys. An atmospheric corrosion rate meter developed to measure the corrosivity of the atmosphere is described. An easily duplicated hole in the square test specimen with a self-induced residual stress was developed.

Poteat, L. E.↗

NASA NTRS1998

Electroformed Nickel Mirrors for the Next Generation Space Telescope

This paper summarizes the work to date on a novel mirror fabrication technique being developed at the Marshall Space Flight Center for potential use on the Next Generation Space Telescope (NGST). This technique involves forming an extremely lightweight mirror by electroplating nickel and nickel based alloys onto a highly polished precision mandrel. The resulting mirror shell can then be backed up with or attached to a lightweight structure to produce a mirror element that is on the order of 15 kg/sq m areal density. Since the mirrors are fabricated from a mandrel (or master), subsequent mirrors can be made with very high economy; this technique is particularly suited to segmented mirrors schemes whereby large apertures are achieved through the deployment of smaller segments. Control of the electroplating process is the key element for producing high quality optics; bath chemistry and real time control of the plating current density yields uniform grained electroforms with zero residual stress. To accomplish this, a special electronic sensor was developed whereby the residual stress can be monitored as the nickel is electrolytically deposited. This information is used in a feedback loop to modulate current density which, in turn, directly governs the residual stress. Details pertaining to this and other aspects of the fabrication of a half meter mirror will be published along with test results and metrology data.

Redmon, John W.↗

DOE OSTI2019

Edge turbulence evolution and intermittency development near the density limit on the HL-2A tokamak

The development of intermittent non-Gaussian processes is researched in the edge turbulence of ohmically heated HL-2A discharges approaching the density limit. As the density limit is approached, the E × B shear flow at the last closed flux surface (LCFS) weakens, a strong positive skewness develops in the scrape-off layer (SOL), and negative skewness develops inside the LCFS of turbulent density fluctuations. A conditional averaging analysis confirms more frequent increased amplitude positive (negative) going density fluctuation activity in the SOL (inside the LCFS) as the density limit is approached. The measured turbulent stress across the edge, LCFS, and SOL region is decomposed into diffusive and residual stress components, and the nonlinear exchange of kinetic energy between the turbulence and the low-frequency E × B shear flow is determined. Residual stress acts to amplify the E × B flow at the LCFS, while the diffusive stress acts to dissipate the flow just inside this region, at the interface between the core plasma and the LCFS. The relative strength of the flow drive associated with the residual stress weakens as the density limit is approached, while the turbulent viscosity associated with the diffusive stress increases at high density. The adiabatic parameter, k z 2 v th 2 / ω ν e , drops significantly to about 0.5 in the SOL when the density limit is approached, indicating a transition from the adiabatic regime to the hydrodynamic regime due to increased collisionality. Such changes enhance the particle transport through the nonadiabatic electron response and hence should end in a stronger edge cooling at fixed edge plasma heat flux.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Effect of Internal Structure on Warpage in a Large-Scale Additive Manufacturing Process With Bio-Derived Composites

Extrusion-based large-format additive manufacturing (LFAM) often results in unintended deformation and failures due to thermal residual stress between layers. This LFAM involves a hot molten polymer deposited on a previously deposited and cooled layer, generating a temperature mismatch between the layers. The temperature discrepancy causes a thermal contraction mismatch, generating thermal residual stress. Due to the residual stress, printed structures experience warpage and delamination Therefore, understanding the heat distribution behavior is essential to preventing undesired deformation and failures. The goal of this study is to investigate the effect of infill patterns on heat distribution and deformation in an LFAM system. Wood fiber-reinforced polylactic acid was used as a sustainable and low-cost reinforcement material. A numerical model was developed to predict the temperature and deformation field with thermo-mechanical properties, which were measured by a dynamic mechanical analysis and a thermal expansion test. Simulations were performed on a box geometry with three different infill patterns. The simulation model was verified with temperature data gathered from an infrared camera. The results show good agreement between predicted and measured temperature profiles. The developed simulation model was applied to a roof tray with different infill patterns for a case study. We found that the different thermal mass distributions resulting from the various infill patterns affected the heat distribution and deformation. These findings contribute to a better understanding of the thermal and mechanical behavior of LFAM.

Jo, Eonyeon↗

DOE OSTI2019

Main-ion intrinsic toroidal rotation across the ITG/TEM boundary in DIII-D discharges during ohmic and electron cyclotron heating

Direct measurements of deuterium main-ion toroidal rotation spanning the linear ohmic to saturated ohmic confinement (LOC-SOC) regime and with additional electron cyclotron heating (ECH) are proposed and compared with the more commonly measured impurity (carbon) ion rotation in DIII-D. Main ions carry the bulk of the plasma toroidal momentum, and hence, the shape of the main-ion rotation is more relevant to the study of angular momentum transport in tokamaks. Both in the LOC regime and with ECH, the main-ion toroidal rotation frequency is flat across the profile from the sawtooth region to the plasma separatrix. However, the impurity rotation profile possesses a rotation gradient, with the rotation frequency being lower near the plasma edge, implying a momentum pinch or negative residual stress inferred from the impurity rotation that differs from the main-ion rotation. In the SOC regime, both the main-ion and impurity rotation profiles develop a deeply hollow feature near the midradius while maintaining the offset in the edge rotation, both implying a positive core residual stress. In the radial region where the rotation gradient changes most dramatically, turbulence measurements show that density fluctuations near the trapped electron mode (TEM) scale are higher when the rotation profile is flat and drop significantly when the plasma density is raised and the rotation profile hollows, consistent with instabilities damped by collisions. Linear initial value gyrokinetic simulations with GYRO indicate that the transition from LOC-SOC in DIII-D occurs as TEMs are replaced by ion temperature gradient (ITG) driven modes from the outer radii inwards as the plasma collisionality increases, Z eff decreases, and the power flow through the ion channel progressively increases due to the electron-ion energy exchange. Gyrofluid modeling with trap gyro-Landau fluid (TGLF) successfully reproduces the plasma profiles at key times in the discharge and in time dependent simulations with predictive TRANSP. TGLF indicates that in the LOC and SOC regimes as well as with ECH, subdominant modes are present and that the plasma is not in a pure TEM or ITG binary state, but rather a more subtle mixed state. Predictions of the main-ion rotation profiles are observed with global nonlinear gyrokinetic simulations using GTS and reveal that the flat rotation is due to oscillatory variation of the turbulent residual stress across the profile, whereas the deeply hollow rotation profile is due to a larger-scale, dipole-like stress profile. In these cases, the predicted and observed main-ion rotation profile is consistent with the balance of turbulent residual stress and momentum diffusion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

Metal Big Area Additive Manufacturing: Process Modeling and Validation

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long range effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress analysis to evaluate the residual stresses and distortions. In this formulation, we assume that physics is directionally coupled, i.e. the effect of stress of the component on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Additive Manufacturing↗

DOE OSTI2015

Low-temperature growth of low friction wear-resistant amorphous carbon nitride thin films by mid-frequency, high power impulse, and direct current magnetron sputtering

The potential of different magnetron sputtering techniques for the synthesis of low friction and wear resistant amorphous carbon nitride (a-CN{sub x}) thin films onto temperature-sensitive AISI52100 bearing steel, but also Si(001) substrates was studied. Hence, a substrate temperature of 150 °C was chosen for the film synthesis. The a-CN{sub x} films were deposited using mid-frequency magnetron sputtering (MFMS) with an MF bias voltage, high power impulse magnetron sputtering (HiPIMS) with a synchronized HiPIMS bias voltage, and direct current magnetron sputtering (DCMS) with a DC bias voltage. The films were deposited using a N{sub 2}/Ar flow ratio of 0.16 at the total pressure of 400 mPa. The negative bias voltage, V{sub s}, was varied from 20 to 120 V in each of the three deposition modes. The microstructure of the films was characterized by high-resolution transmission electron microscopy and selected area electron diffraction, while the film morphology was investigated by scanning electron microscopy. All films possessed an amorphous microstructure, while the film morphology changed with the bias voltage. Layers grown applying the lowest substrate bias of 20 V exhibited pronounced intercolumnar porosity, independent of the sputter technique. Voids closed and dense films are formed at V{sub s} ≥ 60 V, V{sub s} ≥ 100 V, and V{sub s} = 120 V for MFMS, DCMS, and HiPIMS, respectively. X-ray photoelectron spectroscopy revealed that the nitrogen-to-carbon ratio, N/C, of the films ranged between 0.2 and 0.24. Elastic recoil detection analysis showed that Ar content varied between 0 and 0.8 at. % and increased as a function of V{sub s} for all deposition techniques. All films exhibited compressive residual stress, σ, which depends on the growth method; HiPIMS produces the least stressed films with values ranging between −0.4 and −1.2 GPa for all V{sub s}, while CN{sub x} films deposited by MFMS showed residual stresses up to −4.2 GPa. Nanoindentation showed a significant increase in film hardness and reduced elastic modulus with increasing V{sub s} for all techniques. The harder films were produced by MFMS with hardness as high as 25 GPa. Low friction coefficients, between 0.05 and 0.06, were recorded for all films. Furthermore, CN{sub x} films produced by MFMS and DCMS at V{sub s} = 100 and 120 V presented a high wear resistance with wear coefficients of k ≤ 2.3 × 10{sup −5} mm{sup 3}/Nm. While all CN{sub x} films exhibit low friction, wear depends strongly on the structural and mechanical characteristics of the films. The MFMS mode is best suited for the production of hard CN{sub x} films, although high compressive stresses challenge the application on steel substrates. Films grown in HiPIMS mode provide adequate adhesion due to low residual stress values, at the expense of lower film hardness. Thus, a relatively wide mechanical property envelope is presented for CN{sub x} films, which is relevant for the optimization of CN{sub x} film properties intended to be applied as low friction and wear resistant coatings.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Full-f gyrokinetic simulation over a confinement time

A long time ion temperature gradient driven turbulence simulation over a confinement time is performed using the full-f gyrokinetic Eulerian code GT5D. The convergence of steady temperature and rotation profiles is examined, and it is shown that the profile relaxation can be significantly accelerated when the simulation is initialized with linearly unstable temperature profiles. In the steady state, the temperature profile and the ion heat diffusivity are self-consistently determined by the power balance condition, while the intrinsic rotation profile is sustained by complicated momentum transport processes without momentum input. The steady turbulent momentum transport is characterized by bursty non-diffusive fluxes, and the resulting turbulent residual stress is consistent with the profile shear stress theory [Y. Camenen et al., “Consequences of profile shearing on toroidal momentum transport,” Nucl. Fusion 51, 073039 (2011)] in which the residual stress depends not only on the profile shear and the radial electric field shear but also on the radial electric field itself. Based on the toroidal angular momentum conservation, it is found that in the steady null momentum transport state, the turbulent residual stress is cancelled by the neoclassical counterpart, which is greatly enhanced in the presence of turbulent fluctuations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1983

Experimental creep data for a built-up aluminum/titanium structure subjected to heating and loading

Experimental creep, temperature, and strain data resulting from a laboratory experiment on a built-up aluminum/titanium structure are presented. The structure and the experiment are described in detail. A heating and loading experiment lasting approximately six hours is conducted on a test structure. Considerable creep strain resulted from compressive stresses in the heated skin. Large residual stresses were found after the experiment was completed. The residual stresses in the substructure frames were large enough to preclude further cycles of creep experiments with this built-up structure because of concern that the frame webs would buckle.

Jenkins, J. M.↗

DOE OSTI2021

Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition

Cladding hard-surfacing alloys on tool steel is an effective approach to enhance the surface properties of tool steel. In this study, a Co-based alloy was deposited on tool steel by Directed Energy Deposition (DED) following a three-factor three-level design of experiment matrix with varied laser power, scan speed, and powder flow rate. The microstructure of the deposits was characterized using scanning electron microscopy (SEM). The residual stress on the surface of the samples was measured by the X-ray diffraction (XRD) sin2? technique. The parameters that produced promising deposits were used to fabricate samples for tensile test, four-point bending test, Charpy impact test, and hardness measurement. Our result reveals that the processing parameters have a significant role in the residual stress of the coatings. Residual stress reduces with the increase of laser energy density. Cracks were found at samples with energy density below a threshold. Tensile testing of the coating/substrate combined structure reveals fracture at the coatings with an ultimate tensile strength of 633.9 ± 54.7 MPa. The bi-material interface survived the tensile test, indicating a strong interfacial bond. The four-point bending test of coating/substrate laminates shows an ultimate flexure strength of 860.6 ± 36.9 MPa. Cracks initiated from the coatings ignored the interface and penetrated the substrate, suggesting a solid bi-material bond. Charpy impact test shows the absorbed energy of coating/substrate laminates is more than doubled that of the substrate.

36 MATERIALS SCIENCE↗

NASA NTRS2001

Evaluation of a Linear Cumulative Damage Failure Model for Epoxy Adhesive

Recently a significant amount of work has been conducted to provide more complex and accurate material models for use in the evaluation of adhesive bondlines. Some of this has been prompted by recent studies into the effects of residual stresses on the integrity of bondlines. Several techniques have been developed for the analysis of bondline residual stresses. Key to these analyses is the criterion that is used for predicting failure. Residual stress loading of an adhesive bondline can occur over the life of the component. For many bonded systems, this can be several years. It is impractical to directly characterize failure of adhesive bondlines under a constant load for several years. Therefore, alternative approaches for predictions of bondline failures are required. In the past, cumulative damage failure models have been developed. These models have ranged from very simple to very complex. This paper documents the generation and evaluation of some of the most simple linear damage accumulation tensile failure models for an epoxy adhesive. This paper shows how several variations on the failure model were generated and presents an evaluation of the accuracy of these failure models in predicting creep failure of the adhesive. The paper shows that a simple failure model can be generated from short-term failure data for accurate predictions of long-term adhesive performance.

Richardson, David E.↗

NASA NTRS1995

Stress In A Fiber During Curing Of Surrounding Matrix Resin

Experiments run to determine variation in tensile stress in single fiber during curing of matrix resin surrounding fiber. Study part of effort to understand physical mechanisms affecting residual stresses in matrix/fiber composites, with view toward optimizing curing cycles (in particular, optimizing temperature-vs.-time schedules of final cooldowns to ambient temperature) to minimize residual stresses. Results signify primary mechanisms affecting residual stress in fibers are thermal expansion and contraction and cure shrinkage of matrix material.

Bowles, Kenneth J.↗

DOE OSTI2021

Residual strain-stress in manganese steel railway crossing determined by synchrotron and laboratory X-rays

The residual stress within the nose of a worn manganese steel railway crossing was investigated. The macroscopic residual stress at the running surface was determined in areas with and without visual faults by laboratory X-rays. To get information about the penetration depth of the residual stress, synchrotron X-ray diffraction was used to map the distribution of local (within grain) residual strains below the running surface. The laboratory X-ray measurements revealed significant compressive stress on the rail running surface. The synchrotron measurements documented that local strains exist through the entire depth investigated. Relations between residual stress, plastic deformation, and crack formation are analysed, leading to a discussion on potentials/limitations of the two experimental methods for investigations of residual stress in large engineering components.

differentia aperture synchrotron diffraction↗

NASA NTRS1997

Fiber Contraction Approaches for Improving CMC Proportional Limit

The fact that the service life of ceramic matrix composites (CMC) decreases dramatically for stresses above the CMC proportional limit has triggered a variety of research activities to develop microstructural approaches that can significantly improve this limit. As discussed in a previous report, both local and global approaches exist for hindering the propagation of cracks through the CMC matrix, the physical source for the proportional limit. Local approaches include: (1) minimizing fiber diameter and matrix modulus; (2) maximizing fiber volume fraction, fiber modulus, and matrix toughness; and (3) optimizing fiber-matrix interfacial shear strength; all of which should reduce the stress concentration at the tip of cracks pre existing or created in the matrix during CMC service. Global approaches, as with pre-stressed concrete, center on seeking mechanisms for utilizing the reinforcing fiber to subject the matrix to in-situ compressive stresses which will remain stable during CMC service. Demonstrated CMC examples for the viability of this residual stress approach are based on strain mismatches between the fiber and matrix in their free states, such as, thermal expansion mismatch and creep mismatch. However, these particular mismatch approaches are application limited in that the residual stresses from expansion mismatch are optimum only at low CMC service temperatures and the residual stresses from creep mismatch are typically unidirectional and difficult to implement in complex-shaped CMC.

DiCarlo, James A.↗

DOE OSTI2022

Residual elastic strain evolution due to thermal cycling of a ceramic-metal composite (WC-Cu) via high energy X-ray diffraction and analytical modeling

Residual stress, when superimposed with in-service loading, can significantly reduce the lifetime and performance of a component. Ceramic-metal composites are susceptible to residual stresses due to the thermal expansion mismatch of the ceramic and metallic phases. The WC-Cu composite explored in the present study provides a promising combination of thermal conductivity and strength properties, while exhibiting counterintuitive improvements in strength and ductility after thermal cycling. Further, this work quantifies the evolution of the residual elastic strains as a result of processing and cyclic thermal loading in a co-continuous WC-Cu composite through experimental high energy X-ray diffraction and kinetics-based modeling. Both analyses indicate that processing-induced residual tensile stress in the copper phase is relieved upon subsequent thermal cycling, with kinetics modeling revealing the cyclic-dependent nature of the active power-law creep mechanisms. The results indicate that, through stress relaxation, this material system maintains structural stability during thermal cycling. The illustrated kinetics of relaxation can inform general material processors and designers of ceramic-metal composites to minimize detrimental residual stress and improve performance of these material systems.

36 MATERIALS SCIENCE↗

DOE OSTI2019

In Situ Study of the Stress Relaxation During Aging of Nickel-Base Superalloy Forgings

Nickel-base superalloys are conventionally aged in order to develop a favorable microstructure as well as to relieve residual stresses. In this work, neutron diffraction was used to follow the evolution of residual stress during aging in Inconel 718 and Udimet 720LI for the first time by a combination of in situ and ex situ measurements. First, the quench-induced stress profiles were determined for different geometries of Inconel 718 forgings confirming that the amplitude of stress is not significantly affected by the thickness of the component. It was followed by in situ residual stress analysis using neutron diffraction during aging/annealing treatments at 650 °C, 720 °C, and 750 °C. Almost 90 pct of stress relaxation was found to occur primarily during heating to the aging temperature as a result of a combination of plasticity and early-stage creep relaxation. Creep-like stress relaxation was observed to evolve at a diminishing rate during the isothermal treatment of Inconel 718 at 720 °C and 750 °C, while no further stress relaxation occurred at 650 °C. This means that a change in hold temperature might have a more immediate impact on stress relaxation than a change in duration of heat treatment. Finally, the post-aging ex situ measurements showed that a heat treatment at 750 °C for 8 hours reduced the stresses by approximately 70 pct in Inconel 718. By comparison, when heat treating Udimet 720LI in the same way only a 20 pct stress reduction was observed, which is explained by the higher creep resistance of this alloy.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Unveiling the origins of work-hardening enhancement and mechanical instability in laser shock peened titanium

Laser shock-peening (LSP) produces complex gradients in microstructures and residual stresses, which enables fabrication of metallic engineering components with superior mechanical properties. In this work, we use non-destructive and spatially resolved high-energy X-ray diffraction (HE-XRD) to investigate the influences of LSP on microstructure, surface topography, and residual stress for high purity titanium plates. LSP is found to produce large compressive in-plane residual stresses near the peened surface which monotonically decay to zero about 2.5 mm below the surface. These properties were also tracked during in-situ tensile loading, allowing stress partitioning and work-hardening rates to be measured as a function of depth. The surface region is found to have the highest work-hardening rate and remain mechanically stable up to sample failure. In addition, a crystal rigid rotation along a transversal axis of about 27 & nbsp; was observed at large applied strain near the surface region, which is attributed to the formation of denser dispersed shear bands. Furthermore, a sudden drop in tensile stress was observed at a depth of similar to 160 mu m from the LSP surface, indicating the formation of a localized mechanical instability zone (LMIZ). The origin of this LMIZ could be attributed to the increase in shear stress induced by a load transfer from LSP surface due to the formation of denser dispersed shear bands. These observations indicate a localized transition in deformation behavior has occurred from dispersed shear banding to LMIZ and homogeneous deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗