Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “RESIDUAL STRESSES”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of a thermal creep model for aluminum alloy 6061 cladding in U-10Mo monolithic fuel plates

Plate-type fuel elements consisting of a high-density, low-enriched uranium (LEU) U–10Mo-based fuel foil encapsulated in an aluminum alloy (AA) cladding are fabricated using the hot isostatic pressing (HIP) technique. During the HIP process, the fuel plate system is heated to 560 °C, then cooled to room temperature. This heat cycle significantly affects the mechanical properties of the aluminum cladding, and experimental investigations have shown that, post-HIP bonding, the mechanical properties of the aluminum cladding transition from those of AA 6061-T6 to something closer to the O temper. More specifically, the ultimate strength of the cladding decreases while its ductility increases, making it challenging to capture the changes in mechanical behavior and material properties. Understanding the residual stresses generated during the HIP process is critical for assessing the fuel plate’s integrity under various temperature, pressure, and irradiation. To simulate the HIP bonding process, the elastic, plastic, and thermal properties of the cladding are assumed to be similar to those of AA 6061-O temper. However, the primary challenge lies in the lack of available data for the creep model of the AA 6061 cladding during this transient process of HIP. The present study focuses on developing a computational model that predicts the creep behavior of the aluminum cladding in the fuel plates during the HIP process, as cladding creep significantly influences the residual stresses generated in U-10Mo fuel plates during HIP fabrication. Furthermore, as HIP bonding occurs at high temperatures that are nearing the melting point of aluminum, the present work considered a temperature-dependent Arrhenius-type creep model. In particular, a hyperbolic sine creep model is employed to estimate the creep properties of the as-fabricated aluminum cladding. In conclusion, the residual stresses predicted in the U-10Mo fuel when using the newly calibrated creep model closely align with the experimental measurements, validating the model’s accuracy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

A kinetic model for stress generation in thin films grown from energetic vapor fluxes

We have developed a kinetic model for residual stress generation in thin films grown from energetic vapor fluxes, encountered, e.g., during sputter deposition. The new analytical model considers sub-surface point defects created by atomic peening, along with processes treated in already existing stress models for non-energetic deposition, i.e., thermally activated diffusion processes at the surface and the grain boundary. According to the new model, ballistically induced sub-surface defects can get incorporated as excess atoms at the grain boundary, remain trapped in the bulk, or annihilate at the free surface, resulting in a complex dependence of the steady-state stress on the grain size, the growth rate, as well as the energetics of the incoming particle flux. We compare calculations from the model with in situ stress measurements performed on a series of Mo films sputter-deposited at different conditions and having different grain sizes. The model is able to reproduce the observed increase of compressive stress with increasing growth rate, behavior that is the opposite of what is typically seen under non-energetic growth conditions. On a grander scale, this study is a step towards obtaining a comprehensive understanding of stress generation and evolution in vapor deposited polycrystalline thin films.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

The electromechanical behavior of piezoelectric thin film composite diaphragms possessing in-plane stresses

Many piezoelectric microelectromechanical systems (MEMS) measure or generate acoustic signals via the motion of radially non-uniform, thin film composite plates. The composite layers provide piezoelectric actuation, structural support, electrode metallization, passivation, etc. Often, the layers are non-uniform over the plate and contain residual stresses introduced during the fabrication process. Accurate models of non-uniform composite plate mechanics are crucial for predicting and optimizing device performance. In this paper, an analytical solution for a radially non-uniform, piezoelectric, circular composite plate incorporating residual stress is derived. The analytical solution is compared to experimental measurements of a MEMS piezoelectric diaphragm. The results show the improved accuracy of the analytical model when including film stress, the speed of the analytical solution as compared to finite element analysis, the sensitivity of device performance to residual stress and the importance of accurate film stresses as model inputs. Finally, the analytical model presented is useful as a design optimization tool given the efficiency of the computational time, shown to be 275 times less than a comparable finite element analysis.

42 ENGINEERING↗
NASA NTRS2003

The Effect of Tungsten and Niobium on the Stress Relaxation Rates of Disk Alloy CH98

Gas turbine engines for future subsonic transports will probably have higher pressure ratios which will require nickel-base superalloy disks with 1300 to 1400 F temperature capability. Several advanced disk alloys are being developed to fill this need. One of these, CH98, is a promising candidate for gas turbine engines and is being studied in NASA s Advanced Subsonic Technology (AST) program. For large disks, residual stresses generated during quenching from solution heat treatment are often reduced by a stabilization heat treatment, in which the disk is heated to 1500 to 1600 F for several hours followed by a static air cool. The reduction in residual stress levels lessens distortion during machining of disks. However, previous work on CH98 has indicated that stabilization treatments decrease creep capability. Additions of the refractory elements tungsten and niobium improve tensile and creep properties after stabilization, while maintaining good crack growth resistance at elevated temperatures. As the additions of refractory elements increase creep capability, they might also effect stress relaxation rates and therefore the reduction in residual stress levels obtained for a given stabilization treatment. To answer this question, the stress relaxation rates of CH98 with and without tungsten and niobium additions are compared in this paper for temperatures and times generally employed in stabilization treatments on modern disk alloys.

Gayda, John↗
NASA NTRS1992

Mechanical properties of 3C silicon carbide

The residual stress and Young's modulus of 3C silicon carbide (SiC) epitaxial films deposited on silicon substrates were measured by load-deflection measurements using suspended SiC diaphragms fabricated with silicon micromachining techniques. The film's residual stress was tensile and averaged 274 MPa while the in-plane Young's modulus averaged 394 GPa. In addition, the bending moment due to the residual stress variation through the thickness of the film was determined by measuring the deflection of free-standing 3C-SiC cantilever beams. The bending moment was in the range of 2.6 x 10 exp -8 -4.2 x 10 exp-8 N m.

Tong, Lijun↗
DOE OSTI2017

Grinding-induced metallurgical alterations in the binder phase of WC-Co cemented carbides

The metallic binder phase dictates the toughening behavior of WC-Co cemented carbides (hardmetals), even though it occupies a relative small fraction of the composite. Studies on deformation and phase transformation of the binder constituent are scarce. Grinding represents a key manufacturing step in machining of hardmetal tools, and is well-recognized to induce surface integrity alterations. In this work, metallurgical alterations of the binder phase in ground WC-Co cemented carbides have been assessed by a combination of electron back scattered diffraction and transmission electron microscopy techniques. The Co-base binder experiences a martensitic phase transformation from fcc to hcp crystal structure, predominantly in the first 5 μm below the surface. The hcp fraction decreases gradually along a depth of 10 μm. Surface Co displays severe plastic deformation under the highest strain, resulting in formation of nanocrystalline grains in the first micrometer below the surface. Microstructural refinement within the binder phase is observed even at greater depth. Stacking faults were detected in most of the refined grains. The metallurgical alterations of the binder phase modify the local stress distribution during grinding, which affects the discerned subsurface microcracking. The resulting residual stress profile is the sum of multiple subsurface changes, such as phase transformation, severe plastic deformation and grain refinement, where it is discerned that the depth profile of the transformed hcp-Co fraction coincides with the grinding-induced residual stress profile.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Topology Optimization with a Manufacturability Objective

Part distortion and residual stress are critical factors for metal additive manufacturing (AM) because they can lead to high failure rates during both manufacturing and service. We present a topology optimization approach that incorporates a fast AM process simulation at each design iteration to provide predictions of manufacturing outcomes (i.e., residual stress, distortion, residual elastic energy) that can be optimized or constrained. The details of the approach and implementation are discussed, and an example design is presented that illustrates the efficacy of the method.

42 ENGINEERING↗
DOE OSTI2022

Friction Stir Processed Repair Welding of Dry Storage Canisters and Mitigation Strategies: Effect of Engineered Barrier Layer on Environmental Degradation

The proposed project aims to develop a friction sir based repair technique to heal cracks of stainless steel dry storage canisters (DSCs), created by the effect of stress corrosion cracking (SCC). In real service conditions, the welded parts of the canisters become prone to SCC under exposure to aggressive chemical environment. The focus of the project is on developing a mitigation strategy that can be implemented for countering SCC in DSCs following a two-pronged approach: (i) apply friction stir processing (FSP) as a crack repair technique while creating compressive residual stresses at the canister material surface, thus improving resistance against SCC; (ii) add molybdenum and/or nitrogen by friction stir based alloying process to create compositions that improve pitting resistance and thus enhance resistance against SCC. The specific project objectives are listed below: • Investigate FSW of 304L SS a potential repair welding technique of dry storage canisters; • Optimize the FSW parameters to introduce surface compressive stress profiles in the weldments; • Develop a FSP method to surface alloy the 304L with nitrogen and Mo by adding CrN and Mo powders; • Evaluate the surface compressive residual stress profile during FSW and FSP processes; • Evaluate the localized corrosion resistance of the FSW and FSP samples as a function of temperature, chloride concentration, and surface alloy composition; • Evaluate the SCC behavior of the FSW and FSP samples as a function of stress, chloride concentration, and temperature at different surface chemistries and induced residual stress profiles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Stress Relaxation Related to Spontaneous Thin Film Buckling: Correlation between Finite Element Calculations and Micro Diffraction Analysis

Compressive residual stresses generated during thin film deposition may lead to undesirable film damage, such as delamination, buckling, and flaking, ultimately leading to the failure of the device employing the film. Understanding the residual stress generation and role in these damage mechanisms is necessary to preserve thin film integrity and optimize its functional properties. Thin shell theory has been used for decades to predict buckling but the results have not yet been correlated with experimental data since the techniques used to measure stress in metallic films were not able to do so at the required micron scale until recently. Micro scanning X-ray diffraction now enables the direct mapping of the local stress of metallic films. In this paper, finite element method based on thin shell theory and synchrotron X-ray micro diffraction have been used to determine stress maps of thin film buckling patterns. Calculations of the stress distribution in the metallic films have been performed taking into account the buckling geometry determined from optical measurements. Stress distributions over gold blisters and tungsten wrinkles obtained with the two techniques are in fair agreement and allow for the accurate determination of the stress relaxation profile from the bottom to the top of the buckling, validating the thin shell theory model.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Development of Standardized Property Requirements, Measurement Methods, and Reporting Guidance for Coatings

The diverse research programs presently in progress around the world have advanced a large number of coated cladding concepts to various stages of maturity. Industry teams have developed leading coating compositions and geometries, but significant disparity exists in the importance placed on different coating properties, as well as the applicability and standardization of the various methods used to measure these properties. This milestone report provides an initial assessment of the most important coating properties and the experimental methods available for their determination to lay the foundation for standardized reporting and development of comprehensive datasets for modeling efforts. This report has determined that the residual stress of the coating is the most crucial property to investigate, yet it has received minimal attention to date due to a knowledge gap about the growth and formation of the brittle Laves phase under reactor conditions. The significance of residual stress of the coating is further enhanced by its connection and interdependence with other important properties like creep and coating failure mechanisms. This milestone proposes an importance rating for residual stress properties and their associated measurement techniques to fill in knowledge. Furthermore, techniques to investigate the outlined properties are discussed, and their capabilities and limitations are illustrated to provide guidance on their use.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Path length dependent neutron diffraction peak shifts observed during residual strain measurements in U–8 wt% Mo castings

This study reports an angular diffraction peak shift that scales linearly with the neutron beam path length traveled through a diffracting sample. This shift was observed in the context of mapping the residual stress state of a large U–8 wt% Mo casting, as well as during complementary measurements on a smaller casting of the same material. If uncorrected, this peak shift implies a non-physical level of residual stress. A hypothesis for the origin of this shift is presented, based upon non-ideal focusing of the neutron monochromator in combination with changes to the wavelength distribution reaching the detector due to factors such as attenuation. The magnitude of the shift is observed to vary linearly with the width of the diffraction peak reaching the detector. Consideration of this shift will be important for strain measurements requiring long path lengths through samples with significant attenuation. This effect can probably be reduced by selecting smaller voxel slit widths.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Thickness dependence of Al 0.88 Sc 0.12 N thin films grown on silicon

The thickening behavior of aluminum scandium nitride (Al 0.88 Sc 0.12 N) films grown on Si(111) substrates has been investigated experimentally using X-ray diffraction (XRD), transmission electron microscopy (TEM), atomic force microscopy, and residual stress measurement. Al 0.88 Sc 0.12 N films were grown with thicknesses spanning 14 nm to 1.1 um. TEM analysis shows that the argon sputter etch used to remove the native oxide prior to deposition produced an amorphous, oxygen-rich surface, preventing epitaxial growth. XRD analysis of the films show that the A1ScN(002) orientation improves as the films thicken and the XRD A1ScN(002) rocking curve full width half maximum decreases to 1.34 q for the 1.1 pm thick film. XRD analysis shows that the unit cell is expanded in both the a- and c-axes by Sc doping; the a-axis lattice parameter was measured to be 3.172 ± 0.007 A and the c-axis lattice parameter was measured to be 5.000 ± 0.001 A, representing 1.96% and 0.44% expansions over aluminum nitride lattice parameters, respectively. The grain size and roughness increase as the film thickness increases. A stress gradient forms through the film; the residual stress grows more tensile as the film thickens, from -1.24 GPa to +8.5MPa.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Validation Assessment of a Glass-to-Metal Seal Finite-Element Model

Sealing glasses are ubiquitous in high pressure and temperature engineering applications, such as hermetic feed-through electrical connectors. A common connector technology are glass-to-metal seals where a metal shell compresses a sealing glass to create a hermetic seal. Though finite-element analysis has been used to understand and design glass-to-metal seals for many years, there has been little validation of these models. An indentation technique was employed to measure the residual stress on the surface of a simple glass-to-metal seal. Recently developed rate- dependent material models of both Schott 8061 and 304L VAR stainless steel have been applied to a finite-element model of the simple glass-to-metal seal. Model predictions of residual stress based on the evolution of material models are shown. These model predictions are compared to measured data. Validity of the finite- element predictions is discussed. It will be shown that the finite-element model of the glass-to-metal seal accurately predicts the mean residual stress in the glass near the glass-to-metal interface and is valid for this quantity of interest.

42 ENGINEERING↗
DOE OSTI2014

Stress enhanced diffusion of krypton ions in polycrystalline titanium

An experimental investigation on the mutual influence of pre-existing residual stress and point defect following ion implantation is presented. The study has been carried out using polycrystalline titanium samples energetically implanted with krypton ions at different fluences. Ion beam analysis was used to determine the concentration profile of the injected krypton ions, while synchrotron X-ray diffraction has been used for stress determination. Ion beam analysis and synchrotron X-ray diffraction stress profile measurements of the implanted titanium samples show a clear evidence of stress-enhanced diffusion of krypton ions in titanium. It is further observed that for the titanium samples implanted at low fluence, ion implantation modifies the pre-existing residual stress through the introduction of point and open volume defects. The stress fields resulting from the ion implantation act to drift the krypton inclusions towards the surface of titanium.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Influence of Process Parameters and Alloy Composition on Crack Mitigation in Selective Laser Melting

Microcracking and residual stresses are key limitations of laser powder bed fusion (LPBF), an additive manufacturing (AM) technique that uses a high power laser to consolidate successive layers of metal powder. For tungsten, these microcracks find their origin in the combination of a ductile-to-brittle transition (DBT) between 200°C and 400°C and high residual stresses. This work utilized in situ high speed video to capture the cracking mechanisms, and combined the experimental results with thermomechanical modeling to unveil correlations between crack network morphology and process parameter-related variables, such as the local temperature and residual stress distributions. Consequently, preheating and alloying with rare earth oxides were adopted as possible crack mitigation strategies, the efficacy of which was tested against the initial fundamental baseline results. Preheating temperatures above 500°C eliminated all cracking, though this threshold is expected to be higher when tungsten powder (higher oxygen content) is introduced. Alloying can serve as an active oxygen getter in the system, but the rare earth oxides in this work were too large to have significant contributions to crack-mitigation.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Thermal stresses in chemically hardening elastic media with application to the molding process

A method has been formulated for the determination of thermal stresses in materials which harden in the presence of an exothermic chemical reaction. Hardening is described by the transformation of the material from an inviscid liquid-like state into an elastic solid, where intermediate states consist of a mixture of the two, in a ratio which is determined by the degree of chemical reaction. The method is illustrated in terms of an infinite slab cast between two rigid mold surfaces. It is found that the stress component normal to the slab surfaces vanishes in the residual state, so that removal of the slab from the mold leaves the remaining residual stress unchanged. On the other hand, the residual stress component parallel to the slab surfaces does not vanish. Its distribution is described as a function of the parameters of the hardening process.

Levitsky, M.↗
DOE OSTI2015

Development of flaw acceptance criteria for aging management of spent nuclear fuel multiple-purpose canisters

A typical multipurpose canister (MPC) is made of austenitic stainless steel and is loaded with spent nuclear fuel assemblies. The canister may be subject to service-induced degradation when it is exposed to aggressive atmospheric environments during a possibly long-term storage period if the permanent repository is yet to be identified and readied. Because heat treatment for stress relief is not required for the construction of an MPC, stress corrosion cracking may be initiated on the canister surface in the welds or in the heat affected zone. An acceptance criteria methodology is being developed for flaw disposition should the crack-like defects be detected by periodic In-service Inspection. The first-order instability flaw sizes has been determined with bounding flaw configurations, that is, through-wall axial or circumferential cracks, and part-through-wall long axial flaw or 360° circumferential crack. The procedure recommended by the American Petroleum Institute (API) 579 Fitness-for-Service code (Second Edition) is used to estimate the instability crack length or depth by implementing the failure assessment diagram (FAD) methodology. The welding residual stresses are mostly unknown and are therefore estimated with the API 579 procedure. It is demonstrated in this paper that the residual stress has significant impact on the instability length or depth of the crack. The findings will limit the applicability of the flaw tolerance obtained from limit load approach where residual stress is ignored and only ligament yielding is considered.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗