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DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗

DOE OSTI2023

ASF Vaccine Candidate ASFV-G-ΔI177L Does Not Exhibit Residual Virulence in Long-Term Clinical Studies

African swine fever (ASF) is an important disease in swine currently producing a pandemic affecting pig production worldwide. Except in Vietnam, where two vaccines were recently approved for controlled use in the field, no vaccine is commercially available for disease control. Up to now, the most effective vaccines developed are based on the use of live-attenuated viruses. Most of these promising vaccine candidates were developed by deleting virus genes involved in the process of viral pathogenesis and disease production. Therefore, these vaccine candidates were developed via the genomic modification of parental virus field strains, producing recombinant viruses and reducing or eliminating their residual virulence. In this scenario, it is critical to confirm the absence of any residual virulence in the vaccine candidate. This report describes the assessment of the presence of residual virulence in the ASFV vaccine candidate ASFV-G-ΔI177L in clinical studies conducted under high virus loads and long-term observation periods. The results demonstrated that domestic pigs intramuscularly inoculated with 10 6 HAD 50 of ASFV-G-ΔI177L did not show the presence of any clinical sign associated with ASF when observed daily either 90 or 180 days after vaccination. In addition, necropsies conducted at the end of the experiment confirmed the absence of macroscopic internal lesions associated with the disease. These results corroborate the safety of using ASFV-G-ΔI177L as a vaccine candidate.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2017

Residual Gas and Dust around Transition Objects and Weak T Tauri Stars

Residual gas in disks around young stars can spin down stars, circularize the orbits of terrestrial planets, and whisk away the dusty debris that is expected to serve as a signpost of terrestrial planet formation. We have carried out a sensitive search for residual gas and dust in the terrestrial planet region surrounding young stars ranging in age from a few to ∼10 Myr. Using high-resolution 4.7 μ m spectra of transition objects (TOs) and weak T Tauri stars, we searched for weak continuum excesses and CO fundamental emission, after making a careful correction for the stellar contribution to the observed spectrum. We find that the CO emission from TOs is weaker and located farther from the star than CO emission from nontransition T Tauri stars with similar stellar accretion rates. The difference is possibly the result of chemical and/or dynamical effects (i.e., a low CO abundance or close-in low-mass planets). The weak T Tauri stars show no CO fundamental emission down to low flux levels (5 × 10{sup −20} to 10{sup −18} W m{sup −2}). We illustrate how our results can be used to constrain the residual disk gas content in these systems and discuss their potential implications for star and planet formation.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Evolution of Magnetohydrodynamic Turbulence in the Expanding Solar Wind: Residual Energy and Intermittency

We conduct 3D magnetohydrodynamic simulations of decaying turbulence in the context of the solar wind. To account for the spherical expansion of the solar wind, we implement the expanding box model. The initial turbulence comprises uncorrelated counterpropagating Alfvén waves and exhibits an isotropic power spectrum. Our findings reveal the consistent generation of negative residual energy whenever nonlinear interactions are present, independent of the normalized cross helicity σc and compressibility. The spherical expansion facilitates this process. The resulting residual energy is primarily distributed in the perpendicular direction, with S 2 (b) − S 2 (u) ∝ l ⊥ or equivalently –E r ∝ k$^{–2}_{⟂}$. Here S 2 (b) and S 2 (u) are second-order structure functions of magnetic field and velocity respectively. In most runs, S 2 (b) develops a scaling relation S 2 (b) ∝ $l$$^{1/2}_{⊥}$ (E b ∝ k$^{–3/2}_{⟂}$). In contrast, S 2 (u) is consistently shallower than S 2 (b), which aligns with in situ observations of the solar wind. We observe that the higher-order statistics of the turbulence, which act as a proxy for intermittency, depend on the initial σc and are strongly affected by the expansion effect. Generally, the intermittency is more pronounced when the expansion effect is present. Finally, we find that in our simulations, although the negative residual energy and intermittency grow simultaneously as the turbulence evolves, the causal relation between them seems to be weak, possibly because they are generated on different scales.

Interplanetary turbulence↗

NASA NTRS1972

Residual strength and crack propagation tests on C-130 airplane center wings with service-imposed fatigue damage

Fourteen C-130 airplane center wings, each containing service-imposed fatigue damage resulting from 4000 to 13,000 accumulated flight hours, were tested to determine their fatigue crack propagation and static residual strength characteristics. Eight wings were subjected to a two-step constant amplitude fatigue test prior to static testing. Cracks up to 30 inches long were generated in these tests. Residual static strengths of these wings ranged from 56 to 87 percent of limit load. The remaining six wings containing cracks up to 4 inches long were statically tested as received from field service. Residual static strengths of these wings ranged from 98 to 117 percent of limit load. Damage-tolerant structural design features such as fastener holes, stringers, doublers around door cutouts, and spanwise panel splices proved to be effective in retarding crack propagation.

Snider, H. L.↗

NASA NTRS1972

Outlet baffles: Effect on liquid residuals from zero-gravity draining of hemispherically ended cylinders

An experimental investigation was conducted to study the relative effectiveness of various outlet baffles in reducing liquid residuals resulting from the draining of hemispherically ended cylindrical tanks in a weightless environment. Three different baffles were employed. The relative effectiveness of each baffle was determined by comparing the results obtained, in the form of liquid residuals, with results for an unbaffled tank. Data indicate that all the baffles tested reduced residuals. Reductions betweem 10 and 60 percent were obtained, depending on baffle geometry and outlfow Weber number.

Symons, E. P.↗

NASA NTRS1973

The effects of shot-peening residual stresses on the fracture and crack growth properties of D6AC steel

The fracture strength and cyclic crack-growth properties of surface-flawed, shot-peened D6AC steel plate were investigated. For short crack lengths (up to 1.5mm) simple linear elastic fracture mechanics - based only on applied loading - did not predict the fracture strengths. Also, Paris' Law for cyclic crack growth did not correlate the crack-growth behavior. To investigate the effect of shot-peening, additional fracture and crack-growth tests were performed on material which was precompressed to remove the residual stresses left by the shot-peening. Both tests and analysis show that the shot-peening residual stresses influence the fracture and crack-growth properties of the material. The analytical method of compensating for residual stresses and the fracture and cyclic crack-growth test results and predictions are presented.

Elber, W.↗

NASA NTRS1974

Effects of shot-peening residual stresses on the fracture and crack-growth properties of D6AC steel

The fracture strength and cyclic crack-growth properties of surface-flawed, shot-peened D6AC steel plate were investigated. For short crack lengths (up to 1.5 mm) simple linear elastic fracture mechanics - based only on applied loading - did not predict the fracture strengths. Also, Paris' Law for cyclic crack growth did not correlate the crack-growth behavior. To investigate the effect of shot-peening, additional fracture and crack-growth tests were performed on material which was precompressed to remove the residual stresses left by the shot-peening. Both tests and analysis show that shot-peening residual stresses influence the fracture and crack-growth properties of the material. This report presents the analytical method of compensating for residual stresses and the fracture and cyclic crack-growth test results and predictions.

Elber, W.↗

NASA NTRS1976

Longitudinal residual stresses in boron fibers

A method of measuring the longitudinal residual stress distribution in boron fibers is presented. The residual stresses in commercial CVD boron on tungsten fibers of 102, 142, and 203 microns (4, 5.6, and 8 mil) diameters were determined. Results for the three sizes show a compressive stress at the surface 800 to -1400 MN/sq m 120 to -200 ksi), changing monotonically to a region of tensile stress within the boron. At approximately 25 percent of the original radius, the stress reaches a maximum tensile 600 to 1000 MN/sq m(90 to 150 ksi) and then decreases to compressive near the tungsten boride core. The core itself is under a compressive stress of approximately -1300 MN/sq m (-190 ksi). The effects of surface removal on core residual stress and core-initiated fracture are discussed.

Behrendt, D. R.↗

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.↗

NASA NTRS1976

Residual stresses in polymer matrix composite laminates

Residual stresses in composites are induced during fabrication and by environmental exposure. The theory formulated can describe the shrinkage commonly observed after a thermal expansion test. Comparison between the analysis and experimental data for laminates of various material systems indicates that the residual stress-free temperature can be lower than the curing temperature, depending on the curing process. Effects of residual stresses on ply failure including the acoustic emission characteristics are discussed.

Hahn, H. T.↗

NASA NTRS1976

Effect of laminate construction on residual stresses in composites

The effects of ply stacking sequence and ply orientation on the magnitude of lamination residual stresses in graphite/polyimide angle-ply laminates was studied. Embedded strain gage techniques were used to measure thermal strains in laminates of different layup, and residual strains were determined by comparing thermal strains in the angle-ply laminates with those of a unidirectional laminate. The ply stacking sequence did not have an effect on the magnitude of residual strains.

Daniel, I. M.↗

NASA NTRS1978

Residual-flexibility corrections for transient modal rotordynamic models

A modal residual-flexibility approach due to Schwendler and MacNeal (1962) is adapted to account for the 'static' contribution of higher-frequency modes without requiring their integration. It is assumed that each rotor mode acts as a lightly damped second-order system. The additional accuracy provided by residual-flexibility corrections becomes progressively more important as a modal model's actual boundary conditions are forced to deviate from the boundary conditions used to define the rotor's original structural model (stiffness matrix) and its associated eigendata input to the transient modal model. An analysis of the high-pressure-oxygen turbopump of the Space Shuttle main engine shows that the residual-flexibility approach ensures a substantial improvement in accuracy for a relatively moderate increase in computer-time requirements.

Childs, D. W.↗

NASA NTRS1977

Effects of mechanical and thermal cycling on composite and hybrid laminates with residual stresses

The effects of tensile load cycling and thermal cycling on residual stiffness and strength properties of the following composite and hybrid angle-ply laminates were studied: boron/epoxy, boron/polyimide, graphite/low-modulus epoxy, graphite/high-modulus epoxy, graphite/polyimide, S-glass/epoxy, graphite/Kevlar 49/epoxy, and graphite/S-glass/epoxy. Specimens of the first six types were mechanically cycled up to 90% of static strength. Those that survived 10 million cycles were tested statically to failure, and no significant changes in residual strength and modulus were noted. Specimens of all types were subjected to thermal cycling between room temperature and 411 K for the epoxy-matrix composites and 533 K for the polyimide-matrix composites. The residual strength and stiffness remained largely unchanged, except for the graphite/low-modulus epoxy, which showed reductions in both of approximately 35%. When low-temperature thermal cycling under tensile load was applied, there was a noticeable reduction in modulus and strength in the graphite/low-modulus epoxy and some strength reduction in the S-glass/epoxy.

Daniel, I. M.↗

NASA NTRS1980

Calculation of residual principal stresses in CVD boron on carbon filaments

A three-dimensional finite element model of the chemical vapor deposition of boron on a carbon substrate (B/C) is developed. The model includes an expansion of the boron after deposition due to atomic rearrangement and includes creep of the boron and carbon. Curves are presented showing the variation of the principal residual stresses and the filament elongation with the parameters defining deposition strain and creep. The calculated results are compared with experimental axial residual stress and elongation measurements made on B/C filaments. For good agreement between calculated and experimental results, the deposited boron must continue to expand after deposition, and the build up of residual stresses must be limited by significant boron and carbon creep rates.

Behrendt, D. R.↗

NASA NTRS1980

Certain features of the cochleovestibular syndrome in the residual stage of traumatic brain disease

Caloric and rotation tests were applied to the study of the vestibular analyser in 84 patients in the residual state of traumatic disease of the brain. Vestibular disturbances of different degree revealed in 79 patients were as a rule accomplished by cochlear derangement. In the majority of patients the vestibular syndrome was supratentorial with the involvement of the diencephal-hypothalmic, subcortical, and cortical levels of the brain. Vestibular dysfunction correlated with such factors as severity of the sustained craniocerebral traum, duration of the posttraumatic period, and, particularly, with the character of the residual neurological syndrome. In accordance with the latter, it is recommended that vestibular disturbances be treated in the residual period of closed craniocerebral injuries with due regard for the principal pathophysiological mechanisms of the underlying neurological syndrome.

Garshin, M. I.↗

NASA NTRS1980

Calculation of residual principal stresses in CVD boron on carbon filaments

A three-dimensional finite element model of the chemical vapor deposition (CVD) of boron on a carbon substrate (B/C) is developed. The model includes an expansion of the boron after deposition due to atomic rearrangement and includes creep of the boron and carbon. Curves are presented to show how the principal residual stresses and the filament elongation vary as the parameters defining deposition strain and creep are varied. The calculated results are compared with experimental axial residual stress and elongation measurements made on B/C filaments. This comparison requires that for good agreement between calculated and experimental results, the deposited boron must continue to expand after deposition, and that the build-up of residual stresses is limited by significant boron and carbon creep rates.

Behrendt, D. R.↗

NASA NTRS1980

Hg and Pt-metals in meteorite carbon-rich residues - Suggestions for possible host phase for Hg

Carbon-rich and oxide residual phases have been isolated from Allende and Murchison by acid demineralization for the determination of their Hg, Pt-metal, Cr, Sc, Co, and Fe contents. Experimental procedures used eliminated the possibility of exogenous and endogenous contaminant trace elements from coprecipitating with the residues. Large enrichments of Hg and Pt-metals were found in Allende but not in Murchison residues. Hg-release profiles from stepwise heating experiments suggest a sulfide as the host for Hg. Diffusion calculations for Hg based on these experiments indicate an activation energy of 7-8 kcal/mol, the same as that for Hg in troilite from an iron meteorite. This is further support for a sulfide host phase for Hg. Equilibration of Hg with this phase at approximately 900 K is indicated. Reasons for the presence of Pt-metals in noncosmic relative abundances are explored.

Jovanovic, S.↗