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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.

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At least 703 records · Page 39

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DOE OSTI2016

Investigation of the dynamic stress–strain response of compressible polymeric foam using a non-parametric analysis

Dynamic stress–strain response of rigid closed-cell polymeric foams is investigated in this work by subjecting high toughness polyurethane foam specimens to direct impact with different projectile velocities and quantifying their deformation response with high speed stereo-photography together with 3D digital image correlation. The measured transient displacement field developed in the specimens during high stain rate loading is used to calculate the transient axial acceleration field throughout the specimen. A simple mathematical formulation based on conservation of mass is also proposed to determine the local change of density in the specimen during deformation. By obtaining the full-field acceleration and density distributions, the inertia stresses at each point in the specimen are determined through a non-parametric analysis and superimposed on the stress magnitudes measured at specimen ends to obtain the full-field stress distribution. Furthermore, the process outlined above overcomes a major challenge in high strain rate experiments with low impedance polymeric foam specimens, i.e. the delayed equilibrium conditions can be quantified.

42 ENGINEERING↗

DOE OSTI2018

Role of heat treatment and build orientation in the microstructure sensitive deformation characteristics of IN718 produced via SLM additive manufacturing

The benefits of additive manufacturing have been well documented, but prior to these materials being used in critical applications, the deformation mechanisms must be properly characterized. In this work, the role of heat treatment and build orientation of selective laser melting IN718 is investigated through detailed characterization. The microstructure of this material is probed through a combination of electron microscopy to identify the precipitate structure, electron backscatter diffraction to quantify the grain-level features, and synchrotron-based X-ray microcomputed tomography to detect porosity. A high degree of porosity is observed spatially near the free surface of the part, where the contour during the build process meets the interior hatch. Further, microstructure based deformation mechanisms are explored through digital image correlation relative to the grain features after monotonic and cyclic loading and in situ high-energy X-ray diffraction to identify the lattice strain evolution in these materials. Demarcations between the behaviors of the as-built versus post-processed materials are discussed; specifically, in terms of anisotropy with respect to build direction and values of the strength properties, based on the grain morphology, coherent twin formation, and precipitate structure. In conclusion, the presence of dislocation sub-structures within the grains is observed to homogenize deformation within the as-built sample, while strain partitioning is observed during loading of the post-processed sample.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Biaxial deformation in high purity aluminum

The convergence of multiple characterization tools has been applied to investigate the relationship of microstructure on damage evolution in high purity aluminum. The extremely coarse grain size of the disc-shaped sample provided a quasi-two dimensional structure from which the location of surface-measured features could be inferred. In particular, the role of pre-existing defects on damage growth was accessible due to the presence of casting porosity in the aluminum. Micro tomography, electron backscatter diffraction, and digital image correlation were applied to interrogate the sample in three dimensions. Recently micro-bulge testing apparatus was used to deform the pre-characterized disc of aluminum in biaxial tension, and related analysis techniques were applied to map local strain fields. Subsequent post-mortem characterization of the failed sample was performed to correlate structure to damaged regions. We determined that strain localization and associated damage was most strongly correlated with grain boundary intersections and plastic anisotropy gradients between grains. Pre-existing voids played less of an apparent role than was perhaps initially expected. Finally, these combined techniques provide insight to the mechanism of damage initiation, propagation, and failure, along with a test bed for predictive damage models incorporating anisotropic microstructural effects.

36 MATERIALS SCIENCE↗

DOE OSTI2014

In situ strain and temperature measurement and modelling during arc welding

In this study, experiments and numerical models were applied to investigate the thermal and mechanical behaviours of materials adjacent to the weld pool during arc welding. In the experiment, a new high temperature strain measurement technique based on digital image correlation (DIC) was developed and applied to measure the in situ strain evolution. In contrast to the conventional DIC method that is vulnerable to the high temperature and intense arc light involved in fusion welding processes, the new technique utilised a special surface preparation method to produce high temperature sustaining speckle patterns required by the DIC algorithm as well as a unique optical illumination and filtering system to suppress the influence of the intense arc light. These efforts made it possible for the first time to measure in situ the strain field 1 mm away from the fusion line. The temperature evolution in the weld and the adjacent regions was simultaneously monitored by an infrared camera. Finally and additionally, a thermal–mechanical finite element model was applied to substantiate the experimental measurement.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A Comparative Study on Representativeness and Stochastic Efficacy of Miniature Tensile Specimen Testing

Here, in this article, a miniature dog bone tensile coupon design was tested against the existing ASTM standard specimen design. Specimens were prepared from commercially sourced austenitic stainless steel 304 alloy, and a defect-ridden additively manufactured 304L alloy was studied. By utilizing a tensile specimen design that is 1/230th volume of the smallest ASTM E8-04(2016), Standard Test Methods for Tension Testing of Metallic Materials, dog bone specimen, coupled to a digital image correlation (DIC) setup, case studies were performed to compare tensile property measurements and strain field evolution. Whereas yield strength measurements were observed to be similar, post-yield, the ultimate strength measurements and ductility measurements from the miniature specimens were observed to be higher than the ASTM specimen design. Although the strength measurements were comparable, the strain evolution was found to differ in the miniature specimens. Studies to assess effects of varying thickness and defect population were also pursued on the miniature tensile specimen. From the DIC strain field estimations, the peak local strain values at ultimate tensile strength were observed to be increasing with reducing specimen thickness. Testing of defect ridden stainless steel revealed the sensitivity to failure through strain localization and the influence of defect size was captured in the strength measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Clarification of creep deformation mechanism in heat-affected zone of 9Cr steels with In Situ experiments

This work quantified nonuniform creep deformation across the heterogeneous heat-affected zone (HAZ) of Grade 91 steel with sophisticated experiments, including an electric-thermal finite element model–assisted Gleeble thermomechanical simulation and a high-temperature creep testing with in situ digital image correlation (DIC). High temperature creep properties of HAZ sub-zones were quantitatively measured by the DIC. Furthermore, by utilizing peak temperature, hardness, local creep strain, and underlying microstructures, creep deformation mechanisms in HAZ were further understood. DIC measurements reveal a creep-vulnerable zone (CVZ) exposed to a peak temperature of 932°C (close to A C3 ) in the intercritical HAZ experienced the fastest creep strength degradation instead of the soft zone with the lowest hardness prior to creep. The significantly reduced precipitation strengthening from misplacement of undissolved and coarsened M 23 C 6 carbides led to a faster recrystallization of tempered martensite in the CVZ. Weak untransformed tempered martensite (ferrite grains) stabilized by local Cr enrichment from dissolved M 23 C 6 also harmed the CVZ's creep resistance.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Characteristics of Premature Creep Failure in Over-tempered Base Metal of Grade 91 Steel Weldment

Characteristics of premature creep failure in the over-tempered base metal (OT-BM) of a Grade 91 steel weldment are investigated with specially designed creep experiments and advanced microstructure characterization. In situ digital image correlation (DIC) strain measurements reveal that local creep strain as high as 100% accumulated in the OT-BM, compared with only 10% nominal strain over the gauge length. The creep strain rate in the OT-BM is identical to that in the intercritical heat-affected zone and fine-grained heat-affected zone at the secondary creep stage and early tertiary stage, but faster at the late tertiary stage. Microstructural analysis shows that highly recovered microstructure in the OT-BM leads to the lowest hardness, the largest grain size, the lowest fraction of coincidence site lattice boundaries, and the lowest localized strain energy. Dislocation creep and transgranular creep fracture are the dominant deformation and fracture mechanisms in the OT-BM under the current creep testing condition of a low temperature (550 °C) and a high stress (215 MPa).

42 ENGINEERING↗

DOE OSTI2020

The effect of microstructure on the relationship between grain boundary sliding and slip transmission in high purity aluminum

The relationship between grain boundary sliding (GBS) and slip transmission is investigated experimentally at grain boundaries in 99.99% aluminum with a through-thickness, coarse grained microstructure deformed in tension at 190 °C. Using scanning electron microscope enabled digital image correlation (SEM-DIC) and electron backscatter diffraction (EBSD), high resolution strain fields and microstructural information were measured to examine the influence of microstructural neighborhoods on interactions between GBS and slip transmission and strain localization. Several distinct cases are presented that highlight important microstructural factors that govern deformation near grain boundaries. The findings include (1) direct transmission and GBS were anti-compatible and facilitated by opposing boundary types (low misorientation and high energy grain boundaries respectively); (2) increased GBS activity was correlated with decreased indirect transmission behavior; (3) GBS accommodation at triple junctions was enabled by intragranular plasticity; and (4) the local intragranular plastic strain discontinuity between grains determined the magnitude of GBS gradients. Finally, this work provides insight into the nature of these mechanisms and can be used to identify strain transfer criteria that can lead to improved GBS-sensitive crystal plasticity models.

36 MATERIALS SCIENCE↗

DOE OSTI2022

The effects of microstructure on deformation twinning in Mg WE43

The interplay between microstructure and deformation twinning in a WE43-T6 Mg alloy under uniaxial compression was investigated using a combination of scanning electron microscopy with digital image correlation (SEM-DIC) and crystal plasticity finite element (CPFE) simulation. To improve understanding of the statistical characteristics of deformation twin formation, microstructural effects were characterized in over 1000 grains through metrics including the nominal Schmid Factor, grain size, geometric compatibility factor (m'), residual Burgers vector, and the strain accommodated by neighboring grains. There was a strong correlation between the nominal Schmid Factor and both twin activation and variant selection, but this was not fully deterministic. Deformation twinning also exhibited a strong dependence on existing slip and twinning in the neighboring grain and on the m' value. Within the range of grain sizes present in this condition, grain size was determined to have minimal effect on deformation twinning. Finally, statistical analysis of CPFE simulations was used to further investigate microstructural effects on twinning, and qualitatively captured the effect of the nominal Schmid Factor.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding

Transient distortion of thin plate in the welding process usually has a complicated mode and large magnitude. Quantitative measurement and prediction of full-field distortion are challenging and rarely reported up to now. In this study, the out-of-plane distortion of a thin plate during the Tungsten Inert Gas (TIG) welding process was measured using the digital image correlation (DIC) method. A simulation model based on thermal elastic–plastic finite element method (FEM) and DIC measured geometric imperfection were developed for accurate prediction of the transient welding distortion. The numerical results and experimental data agreed very well in both out-of-plane deformation modes and magnitudes of the plate at different stages of welding. The maximum out-of-plane distortion was larger than 4 mm during welding which can cause instability of arc length and heat input. The distance change between welding torch and plate surface was investigated under different initial deflections of the plate before welding. The plate with flat geometry shows the minimum transient and final gap change. In addition, the relationship between heat input and welding distortion was clarified through a series of numerical analyses. As a result, optimization of welding heat input can be performed based on numerical results to avoid excessive welding distortion.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Intern Poster

Digital Image Correlation (DIC) is an optical technique that combines image registration and tracking methods for accurate two-dimensional and three-dimensional changes in images. DIC software can be used to track the contour, deformation, and strain of a sample. In the Advanced Test Reactor (ATR) at INL (Idaho National Laboratory) there exists a small working window of samples that can become irradiated. Hundreds of graphite disks called piggybacks have undergone this irradiation as part of the Advanced Reactor Technologies (ART) program. After irradiation, it is desirable to understand the change in tensile strength as a function of dose. Due to the limited space in the ATR, typical dog bone tensile tests reduce the number of graphite samples from hundreds to tens. However, there does exist an ASTM standard, D8289, which uses disc compression of graphite to estimate the tensile strength of the specimen with the Brazilian Disk test fixture. While only used as an estimate, which is typically off by a third, it is the purpose of this study to identify how to amend D8289 to remove the word "estimate" with the help of DIC.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Mesoscale shock structure in particulate composites

Multiscale experiments in heterogeneous materials and the knowledge of their physics under shock compression are limited. Here, this study examines the multiscale shock response of particulate composites comprised of soda-lime glass particles in a PMMA matrix using full-field high speed digital image correlation (DIC) for the first time. Normal plate impact experiments, and complementary numerical simulations, are conducted at stresses ranging from 1.1 - 3.1 GPa to elucidate the mesoscale mechanisms responsible for the distinct shock structure observed in particulate composites. The particle velocity from the macroscopic measurement at continuum scale shows a relatively smooth velocity profile, with shock thickness decreasing with an increase in shock stress, and the composite exhibits strain rate scaling as the second power of the shock stress. In contrast, the mesoscopic response was highly heterogeneous, which led to a rough shock front and the formation of a train of weak shocks traveling at different velocities. Additionally, the normal shock was seen to diffuse the momentum in the transverse direction, affecting the shock rise and the rounding-off observed at the continuum scale measurements. The numerical simulations indicate that the reflections at the interfaces, wave scattering, and interference of these reflected waves are the primary mechanisms for the observed rough shock fronts.

36 MATERIALS SCIENCE↗

NASA NTRS2023

Assessing Flow Formability of Aerospace Aluminum Alloys via DIC Tensile Testing

Over the past decade, NASA Langley Research Center (LaRC) has championed integrally stiffened cylinder (ISC) technology for single-piece, cryogenic tank barrels on launch vehicles. The current investigation aims to extend the hybrid spin/shear/flow forming process to aircraft fuselage structures, a damage tolerance critical application. The WF Maschinenbau VUD-600® vertical spin/flow forming facility recently established at LaRC represents a reasonable sub-scale facsimile of the ISC deformation process for research and development (R&D) purposes. The objective of this study is to explore whether tensile testing with digital image correlation (DIC) is an effective way to rank the formability of candidate aerospace Al alloys and expedite empirical forming trials. Specific tensile data, such as reduction of area, strain hardening exponent, and modulus of resilience, are used as formability metrics for a variety of alloy/temper/product form combinations. Results from high-strength aluminum alloys AA 2139, AA 2050, AA 2043 and AA 2219 are compared with the medium-strength, highly formable AA 6061 benchmark. Rolled, forged and cast preform materials in both the -O temper (fully annealed) and -T4 temper (solution-treated, quenched, and naturally aged) conditions are evaluated. AA 2139 plate in the -T4 temper emerges as the top-ranked material, based on the criteria selected. Starting with preforms in the -T4 temper will result in flow-formed material exhibiting mechanical properties closer to aircraft fuselage requirements. The optimum balance between strength and damage tolerance may also be achieved via post-forming procedures that avoid quenching and stretching.

Aluminum alloys↗

DOE OSTI2022

Measuring representative volume elements from high-resolution grain-scale strain fields

Most crystalline materials present a highly heterogeneous response at the microscale, which can be affected by both internal factors (such as microstructural parameters) and external factors (such as loading). Relating microscale inhomogeneities to the macroscale response of a material requires the use of homogenisation techniques, usually based on the concept of a representative volume element (RVE)—the smallest volume of material that represents the global average response. Here, in this work, we present a new and robust experimental method of measuring the size of a strain-based RVE from high-resolution grain-scale strain fields obtained using digital image correlation (DIC). The proposed method is based on the statistical (stereological) nature of the RVE, which has been widely adopted in numerical studies, and involves dividing a strain field into randomly selected regions of varying sizes and statistically analysing the distributions of average strains within them. To validate the new method, we generate a large number of synthetic strain fields from a fractional Gaussian noise algorithm. The proposed stereological method is shown to be capable of producing reliable RVE measurements from a very large range of possible microscale strain fields while at the same time being robust in that it can produce RVE measurement results even in cases where other existing methods may be unable to do so. The proposed method has a low field-of-view requirement, only needing a field-of-view about 1.2 times as large as the RVE to produce reliable measurements. In addition, the stereological method offers significant flexibility since its statistical nature allows for control over how strict the RVE measurement should be in each case.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Microstructure Clones

Background: A material’s microstructure drives its material performance. Contemporary crystal plasticity experiments compare full-field strain measurements of polycrystal specimens to models. Because each specimen is unique, it is impossible to know which features of the observed deformation are deterministic vs statistical; thus, differences between model and experiment may or may not be significant. Objective: This paper introduces the invention of microstructure clones. Microstructure clones are 2D oligocrystal specimens that have nearly identical microstructures to remedy the aforementioned experimental limitations. Having specimens with nearly identical microstructures will allow for multiple destructive tests of a microstructure (either as repeats or intentionally different experiments), an ability to “see the future” by providing insight into how a specimen will deform, variability quantification, and experimental investigations of response to small microstructural changes. Methods: This work introduces microstructure clones. Repeatability of these clones is demonstrated in tensile bars of pure nickel. Local strain measurements from digital image correlation are compared between clone specimens and compared to results from a crystal plasticity finite element model. Results: Two sets of microstructure clones were tested in this study and displayed very consistent deformation responses within each clone set. Small observed differences in deformation invite investigation into microstructure stochasticity and the effect of small microstructural and loading differences. Conclusions: Microstructure clones represent a significant shift in understanding structure–property relationships. This work reshapes experimental crystal plasticity to allow for experiments that control for specific variables, quantification of microstructural stochasticity (and other sources of stochasticity), and opportunities for replicating experiments.

Crystal Plasticity↗

DOE OSTI2020

Experimental investigation of multi-scale strain-field heterogeneity in rocks

Rocks have inherently heterogeneous micro-structures. The mechanical response of these heterogeneous micro-structures primarily governs the overall macroscopic behavior of intact rocks, as these features cause heterogeneity in the distribution of stress and strain within a rock volume. These attributes have generally been studied through numerical tools, but in this study, the stress-induced multi-scale spatial heterogeneity in the strain-field of three types of rocks was analyzed experimentally. The full-field non-contact strain measurement approach of 2D Digital Image Correlation (DIC) was employed for real-time evaluation of the progression of strain-field heterogeneity across the surface of the rock specimens when subjected to uniaxial compression. The results show that the strain-field heterogeneity is a characteristic of the inherent heterogeneity of the rock specimens, and that it amplifies with the magnitude of stress applied on the rock specimens. The changes in the strain-field heterogeneity with loading were consistent with established microcrack evolution processes in the rock specimens. The statistical fluctuation in the strain-field heterogeneity of the three rocks at varying gauge lengths (GL) was then analyzed for the determination of the Representative Volume Element (RVE) length-scale at increasing load levels. The evolution of the RVE length-scale with loading facilitates an objective way of determination of the stress at which the strain-field heterogeneity increases and begins to influence the overall global response of the material. The RVE length-scale variation with loading showed that at the RVE length-scale reaches the specimen-scale at load levels well below the peak strength.

2D-digital image correlation↗

DOE OSTI2019

Data clustering for the high-resolution alignment of microstructure and strain fields

The emergence of small-scale deformation mapping by a combination of scanning electron microscopy and digital image correlation (SEM-DIC) has enabled full-field investigations into the complex roles of microstructure on microscale deformation mechanisms. However, these investigations are hindered by errors in alignment between the microstructure data, generally acquired by electron backscatter diffraction (EBSD), and the microscale strain data obtained by SEM-DIC. Distortions, stitching artifacts, and spatial resolution differences between microstructure and strain fields can lead to misalignments on the order of μms. This alignment uncertainty introduces error into microstructure-strain localization analyses and precludes the examination of deformation mechanisms near grain boundaries. To improve alignment between EBSD-obtained grain boundaries and SEM-DIC strain data, an approach was created wherein a mantle was first established around the EBSD-acquired grain boundaries. Strain data was then clustered within this mantle using a k-means algorithm to identify grain boundary strain localization, and these boundary points were fit to obtain a continuous curve for each individual boundary. Clustered point outliers, such as those due to grain boundary-local dislocation slip, were statistically identified by using an absolute error threshold and removed from the grain boundary fit. The ending identification of grain boundaries in the microscale strain data is significantly improved from EBSD-identified boundaries.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Experimental evaluation of localized creep deformation in grade 91 steel weldments

Spatially resolved measurement of localized creep deformation in heterogeneous creep resistant steel weldments is crucial but challenging for lifetime assessments of critical steam components in power plants. Here, experimental approaches were established to quantitatively evaluate commonly observed localized creep deformation in multi-pass Grade 91 steel weldments. An in-situ digital image correlation (DIC) system was utilized with a creep testing frame to monitor and measure both full-field strain and localized strain accumulation across the weldments during long-term creep testing at elevated temperatures. The in situ DIC method measured not only the creep deformation behavior of the weld metal, heat affected zone (HAZ), and base metal, but also creep strain evolution for each sub-region within the HAZ itself, including coarse-grained HAZ, fine-grained HAZ (FGHAZ), and intercritical HAZ (ICHAZ). The DIC results revealed that local creep strain in the ICHAZ reached up to 90% strain before final rupture, whereas nominal creep strain measured by the standard extensometer of the tested cross-weld specimen was below 10%, indicative of Type IV cracking of the Grade 91 weld. Microstructural analyses revealed that the faster creep degradation/deformation in the HAZ was caused mainly by accelerated matrix grain recrystallization/growth and a reduced pinning effect from the segregated and coarsened precipitates in the FGHAZ and ICHAZ. The ultimate creep rupture occurred in the ICHAZ owing to its lowest creep resistance induced by the largest recrystallized grain size, the lowest fraction of coincidence site lattice, and the lowest local strain energies/dislocation densities.

36 MATERIALS SCIENCE↗