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NASA NTRS2012

Accelerated Aging in Electrolytic Capacitors for Prognostics

The focus of this work is the analysis of different degradation phenomena based on thermal overstress and electrical overstress accelerated aging systems and the use of accelerated aging techniques for prognostics algorithm development. Results on thermal overstress and electrical overstress experiments are presented. In addition, preliminary results toward the development of physics-based degradation models are presented focusing on the electrolyte evaporation failure mechanism. An empirical degradation model based on percentage capacitance loss under electrical overstress is presented and used in: (i) a Bayesian-based implementation of model-based prognostics using a discrete Kalman filter for health state estimation, and (ii) a dynamic system representation of the degradation model for forecasting and remaining useful life (RUL) estimation. A leave-one-out validation methodology is used to assess the validity of the methodology under the small sample size constrain. The results observed on the RUL estimation are consistent through the validation tests comparing relative accuracy and prediction error. It has been observed that the inaccuracy of the model to represent the change in degradation behavior observed at the end of the test data is consistent throughout the validation tests, indicating the need of a more detailed degradation model or the use of an algorithm that could estimate model parameters on-line. Based on the observed degradation process under different stress intensity with rest periods, the need for more sophisticated degradation models is further supported. The current degradation model does not represent the capacitance recovery over rest periods following an accelerated aging stress period.

Celaya, Jose R.↗

DOE OSTI2020

Accelerometer Drift Study

Accelerometers are energy transducers that convert mechanical energy into an electrical signal. That electrical signal is proportional to the amount of mechanical stress the accelerometer was subjected to. Knowing this proportionality allows the electrical signal to be interpreted as an acceleration. There are three types of sensing technologies utilized in capacitors: piezoelectric, piezoresistive and capacitive. In this study, all of the accelerometers utilized are of the piezoelectric type and purchased from one particular vendor, MEGGITT. The piezoelectric effect is the phenomena by which a material generates an electrical charge when subjected to a mechanical stress. A piezoelectric accelerometer will not generate an electrical charge when placed in a static acceleration field because no stress will be placed on the piezoelectric element. However if the acceleration field is dynamic, the piezoelectric element will generate an electrical charge. So the types of accelerations these accelerometers are measuring are dynamic in nature, such as vibrations. Knowledge of dynamic acceleration is useful in characterizing the structural response of some object. The sensitivity of an accelerometer is the ratio of its electrical output to mechanical input. The more sensitive an accelerometer is, the greater the value of the electrical output to a given mechanical input. An accelerometer’s sensitivity is known to drift over time. The objective of this study is to quantify this drift. Questions to answer are: Does the accelerometer become more or less sensitive over time and by how much. This is important to understand because this will establish a time frame of when readings from the accelerometer can be utilized. The larger this time frame is the better because that would preclude the need to purchase accelerometers frequently, which saves on costs. This would further bolster the relationship between MEGGITT and LANL if it is found that MEGGITT produces accelerometers that can be used for a relatively long period of time. This would create less uncertainty in picking a vendor for accelerometers.

42 ENGINEERING↗

DOE OSTI2012

Aging Behavior of Viton{sup R} O-Ring Seals in the 9975 Shipping Package - 12594

The Savannah River Site (SRS) is storing plutonium (Pu) materials in the K-Area Materials Storage (KAMS) facility. The Pu materials were packaged according to the DOE-STD-3013 standard and shipped to the SRS in Type B 9975 packages. The robust 9975 shipping package was not designed for long-term product storage, but it is a specified part of the storage configuration and the KAMS facility safety basis credits the 9975 design with containment. Within the 9975 package, nested stainless steel containment vessels are closed with dual O-ring seals based on Viton{sup R} GLT or GLT-S fluoro-elastomer. The aging behavior of the O-ring compounds is being studied to provide the facility with advanced notice of nonconformance and to develop life prediction models. A combination of field surveillance, leak testing of surrogate fixtures aged at bounding service temperatures, and accelerated-aging methodologies based on compression stress-relaxation and oxygen consumption analysis is being used to evaluate seal performance. A summary of the surveillance program relative to seal aging behavior is presented. The aging behavior of fluoro-elastomer seals based on Viton{sup R} GLT and GLT-S is being studied to develop life prediction models in support of long-term storage of plutonium materials in the 9975 shipping packages at the Savannah River Site. Field surveillance data in combination with accelerated-aging data suggest a significant lifetime for the seals. Typical storage conditions are not anticipated to challenge the leak-tightness of the seals for many years. Early life prediction models based on compression stress relaxation indicate a seal lifetime of ∼12 years at the maximum service temperature predicted (93 deg. C). Seal lifetimes at lower, more realistic conditions are likely significantly longer. Service life predictions based on CSR data are thus far conservative relative to predictions based on time to leakage failure. Surveillance data on packages examined after 6 years in storage show only minor compression set of the O-rings and no significant degradation. Surveillance and testing will continue as needed to validate and refine life prediction models. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2011

Climate Change Impact Uncertainties for Maize in Panama: Farm Information, Climate Projections, and Yield Sensitivities

We present results from a pilot project to characterize and bound multi-disciplinary uncertainties around the assessment of maize (Zea mays) production impacts using the CERES-Maize crop model in a climate-sensitive region with a variety of farming systems (Panama). Segunda coa (autumn) maize yield in Panama currently suffers occasionally from high water stress at the end of the growing season, however under future climate conditions warmer temperatures accelerate crop maturation and elevated CO (sub 2) concentrations improve water retention. This combination reduces end-of-season water stresses and eventually leads to small mean yield gains according to median projections, although accelerated maturation reduces yields in seasons with low water stresses. Calibrations of cultivar traits, soil profile, and fertilizer amounts are most important for representing baseline yields, however sensitivity to all management factors is reduced in an assessment of future yield changes (most dramatically for fertilizers), suggesting that yield changes may be more generalizable than absolute yields. Uncertainty around General Circulation Model (GCM)s' projected changes in rainfall gain in importance throughout the century, with yield changes strongly correlated with growing season rainfall totals. Climate changes are expected to be obscured by the large inter-annual variations in Panamanian climate that will continue to be the dominant influence on seasonal maize yield into the coming decades. The relatively high (A2) and low (B1) emissions scenarios show little difference in their impact on future maize yields until the end of the century. Uncertainties related to the sensitivity of CERES-Maize to carbon dioxide concentrations have a substantial influence on projected changes, and remain a significant obstacle to climate change impacts assessment. Finally, an investigation into the potential of simple statistical yield emulators based upon key climate variables characterizes the important uncertainties behind the selection of climate change metrics and their performance against more complex process-based crop model simulations, revealing a danger in relying only on long-term mean quantities for crop impact assessment.

Maize↗

NASA NTRS1972

Reversed creep deformation behavior of metals.

It is shown that the creep deformation resistance of a variety of metals is reduced by repeated reversed deformation at temperatures above 0.4 Tm, where Tm is the absolute melting temperature of each metal. The reduction of creep deformation resistance due to stress reversals is most prominent at approximately 0.5 Tm where the average creep rate may increase by as much as a factor of twenty due to 50-100 stress reversals. Metallographic studies show that the observed acceleration of creep at high temperatures is in part due to the enhancement of grain boundary sliding as a result of gradual grain boundary migration toward planes of maximum shear stress during reversed creep deformation.

Morrow, J.↗

NASA NTRS1973

Functional changes in systemic and regional (intracranial) circulation accompanying low accelerations

Functional changes in systemic and cerebral hemodynamics were studied with respect to vestibular stresses. The main types of responses, differing qualitatively with respect to the tolerance of test subjects to low accelerations (particularly to Coriolis accelerations), were established. This is of practical importance in the selection of aircraft and space pilots. The data presented sheds light on the physiological mechanisms of adaptation and disturbed compensation during vestibular stimulation. Further studies in this important field of aerospace medicine are outlined.

Usachev, V. V.↗

DOE OSTI2016

Assessment of candidates for target window material in accelerator-driven molybdenum-99 production

NorthStar Medical Technologies is pursuing production of an important medical isotope, Mo-99, through a photo-nuclear reaction of a Mo-100 target using a high-power electron accelerator. The current target utilizes an Inconel 718 window. The purpose of this study was to evaluate other candidate materials for the target window, which separates the high-pressure helium gas inside the target from the vacuum inside the accelerator beamline and is subjected to significant stress. Our initial analysis assessed the properties (density, thermal conductivity, maximum stress, minimum window thickness, maximum temperature, and figure of merit) for a range of materials, from which the three most promising were chosen: Inconel 718, 250 maraging steel, and standard-grade beryllium. These materials were subjected to further analysis to determine the effects of thermal and mechanical strain versus beam power at varying thicknesses. Both beryllium and the maraging steel were calculated to withstand more than twice as high beam power than Inconel 718.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Derivation of improved load transformation matrices for launchers-spacecraft coupled analysis, and direct computation of margins of safety

Load and stress recovery from transient dynamic studies are improved upon using an extended acceleration vector in the modal acceleration technique applied to structural analysis. Extension of the normal LTM (load transformation matrices) stress recovery to automatically compute margins of safety is presented with an application to the Hubble space telescope.

Klein, M.↗

NASA NTRS2001

Improved Method Being Developed for Surface Enhancement of Metallic Materials

Surface enhancement methods induce a layer of beneficial residual compressive stress to improve the impact (FOD) resistance and fatigue life of metallic materials. A traditional method of surface enhancement often used is shot peening, in which small steel spheres are repeatedly impinged on metallic surfaces. Shot peening is inexpensive and widely used, but the plastic deformation of 20 to 40 percent imparted by the impacts can be harmful. This plastic deformation can damage the microstructure, severely limiting the ductility and durability of the material near the surface. It has also been shown to promote accelerated relaxation of the beneficial compressive residual stresses at elevated temperatures. Low-plasticity burnishing (LPB) is being developed as an improved method for the surface enhancement of metallic materials. LPB is being investigated as a rapid, inexpensive surface enhancement method under NASA Small Business Innovation Research contracts NAS3-98034 and NAS3-99116, with supporting characterization work at NASA. Previously, roller burnishing had been employed to refine surface finish. This concept was adopted and then optimized as a means of producing a layer of compressive stress of high magnitude and depth, with minimal plastic deformation (ref. 1). A simplified diagram of the developed process is given in the following figure. A single pass of a smooth, free-rolling spherical ball under a normal force deforms the surface of the material in tension, creating a compressive layer of residual stress. The ball is supported in a fluid with sufficient pressure to lift the ball off the surface of the retaining spherical socket. The ball is only in mechanical contact with the surface of the material being burnished and is free to roll on the surface. This apparatus is designed to be mounted in the conventional lathes and vertical mills currently used to machine parts. The process has been successfully applied to nickel-base superalloys by a team from the NASA Glenn Research Center, Lambda Research, and METCUT Research, as supported by the NASA Small Business Innovation Research Phase I and II programs, the Ultra Safe program, and the Ultra- Efficient Engine Technology (UEET) Program.

Gabb, Timothy P.↗

NASA NTRS1998

Simulation of Crack Propagation in Engine Rotating Components under Variable Amplitude Loading

The crack propagation life of tested specimens has been repeatedly shown to strongly depend on the loading history. Overloads and extended stress holds at temperature can either retard or accelerate the crack growth rate. Therefore, to accurately predict the crack propagation life of an actual component, it is essential to approximate the true loading history. In military rotorcraft engine applications, the loading profile (stress amplitudes, temperature, and number of excursions) can vary significantly depending on the type of mission flown. To accurately assess the durability of a fleet of engines, the crack propagation life distribution of a specific component should account for the variability in the missions performed (proportion of missions flown and sequence). In this report, analytical and experimental studies are described that calibrate/validate the crack propagation prediction capability ]or a disk alloy under variable amplitude loading. A crack closure based model was adopted to analytically predict the load interaction effects. Furthermore, a methodology has been developed to realistically simulate the actual mission mix loading on a fleet of engines over their lifetime. A sequence of missions is randomly selected and the number of repeats of each mission in the sequence is determined assuming a Poisson distributed random variable with a given mean occurrence rate. Multiple realizations of random mission histories are generated in this manner and are used to produce stress, temperature, and time points for fracture mechanics calculations. The result is a cumulative distribution of crack propagation lives for a given, life limiting, component location. This information can be used to determine a safe retirement life or inspection interval for the given location.

Bonacuse, P. J.↗

NASA NTRS1999

Simulation of Crack Propagation in Engine Rotating Components Under Variable Amplitude Loading

The crack propagation life of tested specimens has been repeatedly shown to strongly depend on the loading history. Overloads and extended stress holds at temperature can either retard or accelerate the crack growth rate. Therefore, to accurately predict the crack propagation life of an actual component, it is essential to approximate the true loading history. In military rotorcraft engine applications, the loading profile (stress amplitudes, temperature, and number of excursions) can vary significantly depending on the type of mission flown. To accurately assess the durability of a fleet of engines, the crack propagation life distribution of a specific component should account for the variability in the missions performed (proportion of missions flown and sequence). In this report, analytical and experimental studies are described that calibrate/validate the crack propagation prediction capability for a disk alloy under variable amplitude loading. A crack closure based model was adopted to analytically predict the load interaction effects. Furthermore, a methodology has been developed to realistically simulate the actual mission mix loading on a fleet of engines over their lifetime. A sequence of missions is randomly selected and the number of repeats of each mission in the sequence is determined assuming a Poisson distributed random variable with a given mean occurrence rate. Multiple realizations of random mission histories are generated in this manner and are used to produce stress, temperature, and time points for fracture mechanics calculations. The result is a cumulative distribution of crack propagation lives for a given, life limiting, component location. This information can be used to determine a safe retirement life or inspection interval for the given location.

P J Bonacuse↗

DOE OSTI2020

GPU acceleration of all-electron electronic structure theory using localized numeric atom-centered basis functions

We present an implementation of all-electron density-functional theory for massively parallel GPU-based platforms, using localized atom-centered basis functions and real-space integration grids. Special attention is paid to domain decomposition of the problem on non-uniform grids, which enables compute- and memory-parallel execution across thousands of nodes for real-space operations, e.g. the update of the electron density, the integration of the real-space Hamiltonian matrix, and calculation of Pulay forces. To assess the performance of our GPU implementation, we performed benchmarks on three different architectures using a 103-material test set. We find that operations which rely on dense serial linear algebra show dramatic speedups from GPU acceleration: in particular, SCF iterations including force and stress calculations exhibit speedups ranging from 4.5 to 6.6. For the architectures and problem types investigated here, this translates to an expected overall speedup between 3–4 for the entire calculation (including non-GPU accelerated parts), for problems featuring several tens to hundreds of atoms. Additional calculations for a 375-atom Bi2Se3 bilayer show that the present GPU strategy scales for large-scale distributed-parallel simulations.

42 ENGINEERING↗

DOE OSTI2022

Development of a Small-Aperture Cos-theta Dipole Insert Coil Based on Bi2212 Rutherford Cable and Stress Management Structure

The U.S. Magnet Development Program (US-MDP) is developing high-field accelerator magnets with magnetic fields beyond the limits of Nb3Sn technology based on high temperature superconductor Bi 2 Sr 2 CaCu 2 O 8-x (Bi2212). However, Bi2212 wires and cables are sensitive to transverse stresses and strains, which are substantial in high-field accelerator magnets. To prevent large degradation of the Bi2212 coils and achieve the required field quality, an innovative design which provides turn positioning during coil fabrication and operation and manage azimuthal and radial strains/stresses in the coil has been proposed at FNAL. This paper describes the development of a small-aperture two-layer Bi2212 dipole coil with stress management. The main parameters of the Bi2212 wire and Rutherford cable, the design of coil stress management structure and its plastic model, the coil mechanical analysis in the dipole mirror configuration are presented and discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Unveiling the Fatigue Behavior of 2D Hybrid Organic–Inorganic Perovskites: Insights for Long-Term Durability

2D hybrid organic–inorganic perovskites (HOIPs) are commonly found under subcritical cyclic stresses and suffer from fatigue issues during device operation. However, their fatigue properties remain unknown. Here, the fatigue behavior of (C 4 H 9 -NH 3 ) 2 (CH 3 NH 3 ) 2 Pb 3 I 10 , the archetype 2D HOIP, is systematically investigated by atomic force microscopy (AFM). It is found that 2D HOIPs are much more fatigue resilient than polymers and can survive over 1 billion cycles. 2D HOIPs tend to exhibit brittle failure at high mean stress levels, but behave as ductile materials at low mean stress levels. These results suggest the presence of a plastic deformation mechanism in these ionic 2D HOIPs at low mean stress levels, which may contribute to the long fatigue lifetime, but is inhibited at higher mean stresses. The stiffness and strength of 2D HOIPs are gradually weakened under subcritical loading, potentially as a result of stress-induced defect nucleation and accumulation. The cyclic loading component can further accelerate this process. The fatigue lifetime of 2D HOIPs can be extended by reducing the mean stress, stress amplitude, or increasing the thickness. These results can provide indispensable insights into designing and engineering 2D HOIPs and other hybrid organic–inorganic materials for long-term mechanical durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Operation at Reduced Atmospheric Pressure and Concept of Reliability Redundancy for Optimized Design of Insulation Systems

Electrified transportation is calling for insulation design criteria that is adequate to provide elevated levels of power density, power dynamics and reliability. Increasing voltage levels are expected to cause accelerated intrinsic and extrinsic aging effects which will not be easily predictable at the design stage due to a lack of suitable modeling. Designing reliable insulation systems would require finding solutions able to control accelerated aging due to an unpredictable increase of intrinsic stresses and the onset of extrinsic stresses as partial discharges. This paper proposes the concept of reliability redundancy for the insulation design of aerospace electrical asset components, which is also validated at lower-than-standard atmospheric pressure. The principle is that extrinsic-aging-free design might be achieved upon determining the aging stress or abnormal service stresses distribution and being sure that aging will not generate conditions that can incept extrinsic aging (partial discharges) during operation life. However, such information is never, in practice, fully available to insulation system designers. Hence, especially in critical applications such as electrified aircraft, aerospace, and combat ships a further level of reliability should be added to a partial-discharge-free design, which can consist of the use of corona-resistant materials and/or of life models able to consider the accelerated aging effect of partial discharges (or any other type of extrinsic-accelerated aging factor). Innovative life modeling considering both extrinsic and intrinsic aging stresses, insulating material testing to estimate model parameters, and a metric for quantifying the extent of corona (or partial discharge) resistance can lead to establishing feasibility and limit conditions for optimized or fully reliability-redundant design. It is shown in the paper that if an extrinsic-aging-free design is not feasible, and it is therefore replaced by a redundant design, a further level of reliability redundancy can be provided by effective condition monitoring plans.

Montanari, Gian Carlo↗

NASA NTRS1980

Long-time creep behavior of the niobium alloy C-103

The creep behavior of C-103 was studied as a function of stress, temperature, and grain size for test times to 19000 hr. Over the temperature range 827 to 1204 C and the stress range 6.89 to 138 MPa, only tertiary (accelerating) creep was observed. The creep strain epsilon can be related to time t by an exponential relation epsilon = epsilon(0) + K e raised to power (st) - 1), where epsilon (0) is initial creep strain, K is the tertiary creep strain parameter, and s is the tertiary creep rate parameter. The observed stress exponent 2.87 is similar to the three power law generally observed for secondary (linear) creep of Class I solid solutions. The apparent activation energy 374 kj/g mol is close to that observed for self diffusion of pure niobium. The initial tertiary creep rate was slightly faster for fine grained than for coarse-grained material. The strain parameter K can be expressed as a combination of power functions of stress and grain size and an exponential function of temperature. Strain time curves generated by using calculated values for K and s showed reasonable agreement with observed curves to strains of at least 4 percent. The time to 1 percent strain was related to stress, temperature, and grain size in a similar manner as the initial tertiary creep rate.

Titran, R. H.↗

DOE OSTI2014

New solutions with accelerated expansion in string theory

We present concrete solutions with accelerated expansion in string theory, requiring a small, tractable list of stress energy sources. We explain how this construction (and others in progress) evades previous no go theorems for simple accelerating solutions. Our solutions respect an approximate scaling symmetry and realize discrete sequences of values for the equation of state, including one with an accumulation point at w = –1 and another accumulating near w = –1/3 from below. In another class of models, a density of defects generates scaling solutions with accelerated expansion. Here, we briefly discuss potential applications to dark energy phenomenology, and to holography for cosmology.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2017

Assessment of Vertical Mesh Refinement in Concurrently Nested Large-Eddy Simulations Using the Weather Research and Forecasting Model

To facilitate multiscale simulation using the Weather Research and Forecasting Model, vertical mesh refinement for one-way concurrent nested simulation was recently introduced. Grid refinement in the vertical dimension removes the requirement of different grid aspect ratios on the bounding versus the nested domain, such that results from refinement are in the horizontal directions only, and thereby can also reduce numerical errors on the bounding domain arising from large aspect ratios in the presence of complex terrain. Herein, the impacts of vertical grid refinement on the evolving downstream flow in nested large-eddy simulations are evaluated in relation to other model configuration choices, including turbulence subfilter-scale (SFS) stress models, mesh configuration, and alternative methods for calculating several near-surface flow parameters. Although vertical nesting requires coarsening of the vertical grid on the bounding domain, leading to a smaller range of resolved turbulence scales in the nest’s lateral boundary conditions, parameter values within the nested domains are generally only minimally impacted, relative to nesting using the same vertical grid on each domain. Two dynamic SFS models examined herein generally improved the simulated mean wind speed, turbulence kinetic energy, stresses and spectra, on both domains, and accelerated equilibration rates within nested domains, relative to two constant coefficient models. A new method of extrapolating horizontal velocity components to near-surface locations at nested domain lateral boundaries, and a correction to the calculation of deformation elements near the surface, are each shown to slightly alter the mean parameter values, yet only minimally impact equilibration rates within the nested domain.

14 SOLAR ENERGY↗