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Results for “RESIDUAL STRESSES”

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NASA NTRS1990

Large-eddy simulation of transitional channel flow

A large-eddy simulation (LES) of transition in plane channel flow was carried out. The LES results were compared with those of a fine direct numerical simulation (DNS), and with those of a coarse DNS that uses the same mesh as the LES, but does not use a residual stress model. While at the early stages of transition, LES and coarse DNS give the same results: the presence of the residual stress model was found to be necessary to predict accurately mean velocity and Reynolds stress profiles during the late stages of transition (after the second spike stage). The evolution of single Fourier modes is also predicted more accurately by the LES than by the DNS. As small scales are generated, the dissipative character of the residual stress starts to reproduce correctly the energy cascade. As transition progresses, the flow approaches its fully developed turbulent state, the subgrid scales tend towards equilibrium, and the model becomes more accurate.

Piomelli, Ugo↗

NASA NTRS1987

Comparison of measured temperatures, thermal stresses and creep residues with predictions on a built-up titanium structure

Temperature, thermal stresses, and residual creep stresses were studied by comparing laboratory values measured on a built-up titanium structure with values calculated from finite-element models. Several such models were used to examine the relationship between computational thermal stresses and thermal stresses measured on a built-up structure. Element suitability, element density, and computational temperature discrepancies were studied to determine their impact on measured and calculated thermal stress. The optimum number of elements is established from a balance between element density and suitable safety margins, such that the answer is acceptably safe yet is economical from a computational viewpoint. It is noted that situations exist where relatively small excursions of calculated temperatures from measured values result in far more than proportional increases in thermal stress values. Measured residual stresses due to creep significantly exceeded the values computed by the piecewise linear elastic strain analogy approach. The most important element in the computation is the correct definition of the creep law. Computational methodology advances in predicting residual stresses due to creep require significantly more viscoelastic material characterization.

Jenkins, Jerald M.↗

DOE OSTI2018

In-situ neutron diffraction characterization of temperature dependence deformation in α-uranium

In-situ strain neutron diffraction measurements were conducted at temperature on specimens coming from a clock-rolled α-uranium plate, and Elasto-Plastic Self-Consistent (EPSC) modeling was employed to interpret the findings. The modeling revealed that the active slip systems exhibit a thermally activated response, while deformation twinning remains athermal over the temperature ranges explored (25-150 °C). The modeling also allowed assessment of the effects of thermal residual stresses on the mechanical response during compression. These results are consistent with those from a prior study of room-temperature deformation, indicating that the thermal residual stresses strongly influence the internal strain evolution of grain families, as monitored with neutron diffraction, even though accounting for these residual stresses has little effect on the macroscopic flow curve, except in the elasto-plastic transition.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Effects of Co contents on the microstructures and properties of the electrodeposited NiCo–Zr composite coatings

Highlights: • The novel NiCo–Zr coatings were prepared by electro-deposition. • Surface morphology, crystal structure, grain size and microstrain were examined. • Texture, residual stress and corrosion resistance were investigated. • Addition of Co increased the hardness and corrosion resistance of the coatings. - Abstract: In this study, the NiCo–Zr composite coatings were prepared from the electrolytes with different Co{sup 2+} concentrations by electrodeposition method. The effects of Co contents on the crystal structure, surface morphology, grain size, microstrain and residual stress were examined by X-ray diffractometer (XRD), field emission scanning electron microscopy (FESEM), Energy dispersive X-ray spectroscopy (EDX) and atomic force microscope (AFM). The corrosion resistance of the composite coatings was also examined by the potentiodynamic polarization and electrochemical impedance (EIS) measurements. The results revealed that the crystal structures of the coatings were dependent on the Co contents and addition of Co content of 58 wt% resulted in the formation of hexagonal (hcp) Co. The increasing Co contents in the NiCo–Zr composite coatings resulted in the smoother and more compact surface, decreased the grain size and increased the microstrain. The micro-hardness and residual stress also increased with increasing Co contents. The addition of Co increased the corrosion resistance of the NiCo–Zr composite coatings compared with the Ni–Zr coating while the corrosion resistance of the NiCo–Zr composite coatings decreased as the Co contents increased.

36 MATERIALS SCIENCE↗

DOE OSTI2014

CRADA Final Report for CRADA Number NFE-08-01671 Materials for Advanced Turbocharger Designs

Results were obtained on residual stresses in the weld of the steel shaft to the Ni-based superalloy turbine wheel for turbochargers. Neutron diffraction studies at the HFIR Residual Stress Facility showed asymmetric tensile stresses after electron-beam welding of the wheel and shaft. A post-weld heat-treatment was found to relieve and reduce the residual stresses. Results were also obtained on cast CF8C-Plus steel as an upgrade alternative to cast irons (SiMo, Ni-resist) for higher temperature capability and performance for the turbocharger housing. CF8C-Plus steel has demonstrated creep-rupture resistance at 600-950oC, and is more creep-resistant than HK30Nb, but lacks oxidation-resistance at 800oC and above in 10% water vapor. New modified CF8C-Plus Cu/W steels with Cr and Ni additions show better oxidation resistance at 800oC in 10% water vapor, and have capability to higher temperatures. For automotive gasoline engine turbocharger applications, higher temperatures are required, so at the end of this project, testing began at 1000oC and above.

diesel engine applications↗

DOE OSTI2021

Hydrogen-assisted fracture resistance of pipeline welds in gaseous hydrogen

Fracture resistance of pipeline welds from a range of strength grades and welding techniques was measured in air and 21 MPa hydrogen gas, including electric resistance weld of X52, friction stir weld of X100 and gas metal arc welds (GMAW) of X52, X65 and X100. Welds exhibited a decrease in fracture resistance in hydrogen compared to complementary tests in air. A general trend was observed that fracture resistance in 21 MPa hydrogen gas decreased with increasing yield strength. To accommodate material constraints, two different fracture coupon geometries were used in this study, which were shown to yield similar fracture resistance values in air and 21 MPa hydrogen gas; values using different coupons resulted in less than 15% difference. In addition, fracture coupons were removed from controlled locations in select welds to examine the potential influence of orientation and residual stress. The two orientations examined in the X100 GMAW exhibited negligible differences in fracture resistance in air and, similarly, negligible differences in hydrogen. Residual stress exhibited a modest influence on fracture resistance; however, a consistent trend was not observed between tests in air and hydrogen, suggesting further studies are necessary to better understand the influence of residual stress. A comparison of welds and base metals tested in hydrogen gas showed similar susceptibility to hydrogen-assisted fracture. The overall dominant factor in determining the susceptibility to fracture resistance in hydrogen is the yield strength.

08 HYDROGEN↗

DOE OSTI2025

Multiplexing Focusing Analyzer for Efficient Stress-Strain Measurements

Statement of the problem or situation that is being addressed. Although thermal and cold neutron scattering is widely used and is critical for success in many areas of materials science and engineering, relatively low neutron fluxes severely limit applications of not only laboratory neutrons generators, but also large national neutron facilities. State-of-the-art thermal and cold neutron sources are large expensive national facilities, which serve diverse community of scientific and industrial users. The constant need to improve the instruments performance, stems from the fact that neutron methods are gaining in popularity, and becoming more and more powerful, while new neutron sources are not being constructed to keep pace with the developments and needs of the scientific community. Small research reactors at universities and National Labs, and laboratory-based neutron generators, are necessary not only for education and training, but also when samples cannot be transported to other facilities. However, the standard neutron techniques, which were developed for high-flux facilities, require much higher efficiencies to be used effectively with the low fluxes of small sources. Thus, the efficient use of neutron sources, such as with our proposed analyzer, is important for the progress and broader use of these neutron techniques. General statement of how this problem is being addressed. We propose to design and demonstrate novel diffractive optical device, which will enable very efficient residual stress neutron diffractometers. The proposed device will be a multi-foil analyzer, where each foil is constructed of focusing bent single crystals of Si. Such device will enable polychromatic residual stress neutron diffraction. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast measurements for determining residual stress tensors, raster large samples or screen multiple samples. Commercial Applications and Other Benefits The outcome of this project would be the demonstration of commercial devices, novel neutron optical components, which could be utilized to improve the performance of existing instruments or build novel neutron scattering instruments at DOE neutron facilities and commercial laboratory neutron sources. These new devices will widen the scope of research conducted using neutrons and enable measurements not feasible at present. Summary for Members of Congress Thermal and cold neutron beams are a powerful materials science probe, which provide unique information about the structure of matter. The proposed innovations expand the reach of neutron-based investigations to new materials and industries by enabling new instrumentation capabilities, thereby greatly enhancing and expanding the role of small, laboratory-based neutron instrumentation, and improving education and training of neutron users.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2002

Effects of Thermomechanical History on the Tensile Behavior of Nitinol Ribbon

Shape memory alloys (SMAs) have enormous potential for a wide variety of applications. A large body of work exists on the characterization of the microstructure and stress-strain behavior of these alloys, Nitinol (NiTi) in particular. However, many attributes of these materials are yet to be fully understood. Previous work at NASA Langley Research Center (LaRC) has included fabrication of hybrid composite specimens with embedded Nitinol actuators and modeling of their thermomechanical behavior. An intensive characterization effort has been undertaken to facilitate fundamental understanding of this alloy and to promote implementation of Nitinol in aerospace applications. Previous work revealed attributes of the Nitinol ribbon that were not easily rationalized with existing data in the literature. In particular, tensile behavior at ambient temperature showed significant dependence on the thermomechanical history prior to testing. The present work is focused on characterizing differences in the microstructure of Nitinol ribbons exposed to four different thermomechanical histories and correlation of the microstructure with tensile properties. Differential scanning calorimetry (DSC) and x-ray diffraction (XRD) analysis were employed to rationalize the microstructures present after exposure to various thermomechanical histories. Three of the Nitinol ribbon conditions were reversible upon heating (in the DSC) through the reverse transformation temperature (A(sub f) to transform the microstructure to austenite. However, the prior thermomechanical conditioning for the Nitinol ribbon that reflected the entire fabrication procedure (4% thermal cycle condition) was found to have an irreversible effect on the microstructure, as it remained unchanged after repeated complete thermal cycles. Tensile tests were conducted to determine the effect of prior thermomechancal conditioning on both the tensile behavior of the Nitinol ribbons and the stress state of the microstructure. The stress-strain behavior of the Nitinol actuators appears to be governed by the interplay between two major variables: namely, microstructural constituents such as the R-phase and the martensite; and the stress state of these constituents (whether twinned with low residual stresses, or detwinned with high residual stresses). The most significant difference in the stress-strain behavior of the four conditions, the critical stress required to achieve an initial stress plateau, was found to depend on both the amount and stress state (twinned or detwinned) of R-phase present in the initial microstructure. Thus, the effect of prior thermomechanical processing is critical to the resulting tensile behavior of the Nitinol actuator. For numerical modeling inputs one must take into account the entire fabrication process on the Nitinol actuator.

Lach, Cynthia L.↗

DOE OSTI2019

High Resolution Mapping of Orientation and Strain Gradients in Metals by Synchrotron 3D X-ray Laue Microdiffraction

Synchrotron 3D X-ray Laue microdiffraction, available at beamline 34-ID-E at Advanced Photon Source in Argonne National Laboratory, is a powerful tool for 3D non-destructive mapping of local orientations and strains at sub-micron scale in the bulk. With this technique, it is possible to study local residual stresses developed during manufacturing or while in service due to interactions between, for example, different phases and/or grains with different orientations in materials containing multiple or single phase(s). Such information is essential for understanding mechanical properties and designing advanced materials, but is largely non-existent in the current generation of materials models. In the present paper, the principle and experimental set-up of the 3D microdiffraction are introduced, followed by a description of a method for quantification of the local plastic deformation based on high-angular-resolution orientation maps. The quantification of local residual stresses in two model materials, ductile cast iron (two phases) and partially recrystallized pure nickel (single phase), using 3D microdiffraction will then be presented. The results show that 3D microdiffraction is important for understanding the origin of local residual stresses and to relate them to the microstructural evolution. Finally, the limitations of the 3D microdiffraction on the current generation synchrotron source and new possibilities after the synchrotron upgrade are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Large-Scale Welding Process Simulation by GPU Parallelized Computing

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1982

Effect of shot peening on surface fatigue life of carburized and hardened AISI 9310 spur gears

Surface fatigue tests were conducted on two groups of AISI 9310 spur gears. Both groups were manufactured with standard ground tooth surfaces, with the second group subjected to an additional shot peening process on the gear tooth flanks. The gear pitch diameter was 8.89 cm (3.5 in.). Test conditions were a gear temperature of 350 K (170 F), a maximum Hertz stress of 1.71 billion N/sq m (248,000 psi), and a speed of 10,000 rpm. The shot peened gears exhibited pitting fatigue lives 1.6 times the life of standard gears without shot peening. Residual stress measurements and analysis indicate that the longer fatigue life is the result of the higher compressive stress produced by the shot peening. The life for the shot peened gear was calculated to be 1.5 times that for the plain gear by using the measured residual stress difference for the standard and shot peened gears. The measured residual stress for the shot peened gears was much higher than that for the standard gears.

Townsend, D. P.↗

DOE OSTI2017

The significance of intermetallic compounds formed during interdiffusion in aluminum and magnesium dissimilar welds

Diffusion couples between Al-AA6111 and Mg-AZ31 have been used to perform a comprehensive review of the IMC phases that develop in this system, including; their growth kinetics, texture, residual stresses, and mechanical properties. The new observations made have been compared to data in the literature with the aim of providing an in-depth understanding of the detrimental effects of interfacial reaction in aluminum–magnesium dissimilar welding. Three Al–Mg binary IMC phases were identified, γ-Al{sub 12}Mg{sub 17} and β-Al{sub 3}Mg{sub 2}, as well as ε-Al{sub 30}Mg{sub 23}, which has not been previously reported in inter-diffusion studies. The β phase had the highest growth rate and became the dominant constituent of the IMC layer at longer reaction times. The ε-phase only appeared after extended heat treatment, via transformation at the Al{sub 12}Mg{sub 17}/Al{sub 3}Mg{sub 2} interface. Intrinsic diffusion coefficients of Al and Mg, calculated in the Al{sub 3}Mg{sub 2} phase, confirmed that Al is the faster diffusing species (by an order of magnitude) during IMC growth. Indentation techniques showed that all the IMC phases had extremely low toughness (1/2 ). FIB-assisted ring core milling revealed that both the β-Al{sub 3}Mg{sub 2} and γ-Al{sub 12}Mg{sub 17} phases contained large residual stresses. Their in-situ fracture toughness was consequently found to be asymmetric with lower values parallel to the joint interface. Greater tensile residual stress was measured in the β-Al{sub 3}Mg{sub 2} phase, which, combined with a lower toughness and more rapid growth kinetics, explains why it is generally the ‘weak link’ in Al–Mg dissimilar joints.

36 MATERIALS SCIENCE↗

DOE OSTI2025

XFEM Development for Modeling Crack Growth in Prototypical Welded Components

Nuclear power plant components are subjected to harsh operating environments that can lead to multiple degradation mechanisms in which fracture can play a prominent role. Predicting crack growth is important for assessing the integrity of welded components. The extended finite element method (XFEM) is an important tool for modeling such crack growth, and XFEM capabilities have been developed within the MOOSE framework. This report documents work in the MOOSE XFEM module to model fractures in three-dimensional representations of components using a topologically two-dimensional mesh to define cutting planes. Crack growth algorithms have been implemented to evolve the cutting mesh based on equations for stress corrosion cracking. Additionally, several usability and robustness improvements have been developed to enable three-dimensional fracture simulations. The cutting algorithms were demonstrated on a three-dimensional model of a prototypical reactor component undergoing stress corrosion cracking driven by idealized weld residual stresses. This is an incremental step toward using this capability to model more complex components with residual stresses computed through welding process simulations.

42 - ENGINEERING↗

DOE OSTI2016

Mitigating cutting-induced plasticity in the contour method, Part 2: Numerical analysis

Cutting-induced plasticity can have a significant effect on the measurement accuracy of the contour method. The present study examines the benefit of a double-embedded cutting configuration that relies on self-restraint of the specimen, relative to conventional edge-crack cutting configurations. A series of finite element analyses are used to simulate the planar sectioning performed during double-embedded and conventional edge-crack contour cutting configurations. The results of numerical analyses are first compared to measured results to validate the cutting simulations. The simulations are then used to compare the efficacy of different cutting configurations by predicting the deviation of the residual stress profile from an original (pre-cutting) reference stress field, and the extent of cutting-induced plasticity. Comparisons reveal that while the double-embedded cutting configuration produces the most accurate residual stress measurements, the highest levels of plastic flow are generated in this process. As a result, this cutting-induced plastic deformation is, however, largely confined to small ligaments formed as a consequence of the sample sectioning process, and as such it does not significantly affect the back-calculated residual stress field.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Probing stress and fracture mechanism in encapsulated thin silicon solar cells by synchrotron X-ray microdiffraction

Thin ( < 150 µm) silicon solar cell technology is attractive due to the significant cost reduction associated with it. Consequently, fracture mechanisms in the thin silicon solar cells during soldering and lamination need to be fully understood quantitatively in order to enable photovoltaics (PV) systems implementation in both manufacturing and field operations. Synchrotron X-ray Microdiffraction (µSXRD) has proven to be a very effective means to quantitatively probe the mechanical stress which is the driving force of the fracture mechanisms (initiation, propagation, and propensity) in the thin silicon solar cells, especially when they are already encapsulated. Here in this article, we present the first ever stress examination in encapsulated thin silicon solar cells and show how nominally the same silicon solar cells encapsulated by different polymer encapsulants could have very different residual stresses after the lamination process. It is then not difficult to see how the earlier observation, as reported by Sander et al. (2013) [1], of very different fracture rates within the same silicon solar cells encapsulated by different Ethylene Vinyl Acetate (EVA) materials could come about. Finally, the complete second degree tensor components of the residual stress of the silicon solar cells after lamination process are also reported in this paper signifying the full and unique capabilities of the Synchrotron X-Ray Microdiffraction technique not only for measuring residual stress but also for measuring other potential mechanical damage within thin silicon solar cells.

14 SOLAR ENERGY↗

DOE OSTI2020

Surface Integrity and Oxidation of a Powder Metallurgy Ni-Based Superalloy Treated by Laser Shock Peening

Laser shock peening is a mechanical surface treatment which can induce large compressive residual stresses and microstructural changes in the material by using repetitive shocks from laser pulses. In this work, the surface integrity (surface microstructure, topography, hardness and residual stress) of a laser shock peening treated powder metallurgy Ni-based superalloy was investigated. Laser shock peening treatment introduces large plastic deformation especially at a depth of about 100 μm from the surface, which increases the local hardness. The residual stress from the surface to the interior of the sample was investigated by synchrotron X-ray diffraction. The maximum compressive stress reaches 400 MPa at the surface, while the depth of the compressive stress is about 0.7 mm. Lastly, the oxidation behavior of the treated and untreated samples was evaluated by thermal exposure at 700°C for 312 h. The LSP treatment decreased the thickness of oxide layer, thereby showing improved oxidation resistance.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Laser shock peening effect on the dislocation transitions and grain refinement of Al–Mg–Si alloy

This paper systematically investigates the effect of laser shock peening without coating parameters on the microstructural evolution, and dislocation configurations induced by ultra-high plastic strains and strain rates. Based on an analysis of optical microscopy, polarized light microscopy, transmission electron microscopy observations and residual stress analysis, the significant influence of laser shock peening parameters due to the effect of plasma generation and shock wave propagation has been confirmed. Although the optical microscopy results revealed no significant microstructural changes after laser shock peening, i.e. no heat effect zone and differences in the distribution of second-phase particles, expressive influence of laser treatment parameters on the laser shock induced craters was confirmed. Moreover, polarized light microscopy results have confirmed the existence of well-defined longish grains up to 455 μm in length in the centre of the plate due to the rolling effect, and randomly oriented smaller grains (20 μm × 50 μm) in the surface due to the static recrystallization effect. Laser shock peening is reflected in an exceptional increase in dislocation density with various configurations, i.e. dislocation lines, dislocation cells, dislocation tangles, and the formation of dense dislocation walls. More importantly, the microstructure is considerably refined due to the effect of strain deformations induced by laser shock peening process. The results have confirmed that dense dislocation structures during ultra-high plastic deformation with the addition of shear bands producing ultra-fine (60–200 nm) and nano-grains (20–50 nm). Furthermore, dislocation density was increased by a factor of 2.5 compared to the untreated material (29 × 10{sup 13} m{sup −2} vs. 12 × 10{sup 13} m{sup −2}). - Highlights: • LSPwC imparts high compressive residual stresses up to − 362 ± 31 MPa. • After LSPwC the microstructure is considerably refined via dislocation transitions. • Results confirmed ultra-fine (60–200 nm) and nano-grains (20–50 nm) after LSPwC. • Reasonable agreements between dislocation density and residual stress are obtained.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Thermomechanical Analysis of A-TIG and MP-TIG Welding of 2.25Cr-1Mo Steel Considering Phase Transformation

In the present study, a finite element-based 3D mesh model is used to simulate the effect of welding processes on the temperature distribution, residual stress and distortion in 11-mm-thick 2.25Cr-1Mo steel weld joints. Tungsten inert gas (TIG) and activated-TIG (A-TIG) welding processes were employed for the fabrication of weld joints. Austenite-to-bainite phase transformation is taken into account in the numerical analysis. The heat input fitting tool has been used to calibrate the heat source by matching the simulated weld bead with that of the actual weld bead. Peak temperature was higher at the weld center for A-TIG weld joint, and the weld joint exhibited a sharp temperature gradient at the weld interface. There was good agreement between the predicted and measured thermal cycles. A-TIG and multipass-TIG (MP-TIG) weld joints exhibited similar longitudinal residual stresses in heat affected zone with a difference of 50 MPa. Moreover, A-TIG weld joint fabricated by double-side welding technique employing two passes exhibited reduced distortion than MP-TIG weld joints. A higher magnitude of distortion was in MP-TIG weld joint which was attributed to more weld metal volume caused by more number of weld passes required to fill the V-groove. There was good agreement between the predicted and measured residual stress and distortion values.

36 MATERIALS SCIENCE↗