Effective residual stress prediction validated with neutron diffraction method for metal large-scale additive manufacturing
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36 MATERIALS SCIENCE↗
SEARCH · Engineering Papers
Results for “Elemental analysis”
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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Incorporating defects into model predictions of metal lattice-structured materials
Not Available
36 MATERIALS SCIENCE↗
Intergranular ductile failure of materials with plastically heterogeneous grains
In several precipitation hardened alloys that are susceptible to intergranular ductile failure, precipitation does not always occur uniformly throughout the microstructure, and regions close to grain boundaries may remain precipitate-free. These precipitate-free zones (PFZs) in the material microstructures result in plastically heterogeneous grains, since PFZs are expected to have lower yield strength but higher strain-hardenability compared to the precipitate containing grain interior. Experimentally, the presence of PFZs in precipitation-hardened alloys has been associated with both increase and decrease in materials’ ductility, with or without significant change in the strength. Thus, to understand and rationalize the experimental observations, we have carried out extensive microstructure-based finite element calculations of intergranular ductile failure in materials under tensile loading conditions. In the calculations, both the grain boundaries and PFZs are discretely modeled, and a wide range of the values of yield strength, strain-hardenability and width of PFZs in the material microstructures are analyzed. Our results show that the effects of PFZs on the overall mechanical response of the material strongly depend on the values of yield strength and strain-hardenability of PFZs. Here, there exists an optimum combination of the values of these two parameters that can result in the overall ductility and tensile strength of the material microstructures with PFZs being greater than the microstructures without PFZs.
36 MATERIALS SCIENCE↗
FEA-aided investigation of the effective thermal conductivity in a medium with embedded spheres
For multiple applications in nuclear energy, the ability to accurately represent material behavior with a simplified model is important to facilitate practical engineering-scale simulations. Here, we focus on the homogenized thermal response of a medium containing spherical inclusions, similar to a fuel form (compact or pebble) containing (TRISO) particles. A review on effective thermal conductivity (ETC) modeling is performed considering a random distribution of mono-sized spherical inclusions in a continuous matrix, with a primary focus on the analytical models. Finite element simulations are performed to evaluate each analytical model in varying material conditions. The model predictions are compared with the expected results obtained from the finite element predictions in addition to the Wiener and Hashin-Shtrikman bounds. Lastly, we included a practical discussion on the homogenization applied to a TRISO fuel pebble.
42 ENGINEERING↗
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↗
Comparison of MURR high-assay low-enriched uranium fuel element and design demonstration element irradiation thermo-mechanical analysis predictions
Explore the source record for details and available documents.
Wang, Guanyi↗
Fractal textured surfaces for high temperature corrosion mitigation in molten salts
Not provided.
Energy & Fuels↗
High temperature fracture toughness of single-layer CrAlN and CrAlSiN hard coatings
Hardness and toughness are among of the most important physical properties of hard coatings and it is important to analyze them at temperatures present during coating applications. CrAlN and CrAlSiN are hard coating materials frequently used in high temperature applications. Here, while both possess high oxidation resistance and thermal stability, they differ in their microstructure. In this work, the fracture toughness of magnetron-sputtered single-layer CrAlN and CrAlSiN hard coatings was determined up to 700 °C by in-situ scanning electron microscopy micro-cantilever deflection tests. The results show a decreasing trend of the fracture toughness with increasing temperature. While both coatings' fracture toughness trends are similar up to 400 °C, they diverge at higher temperatures. In general, the evolution of the fracture toughness with increasing temperature shows similarities to the observed changes in hardness in the same temperature range.
36 MATERIALS SCIENCE↗
Regiospecific Cellulose Orientation and Anisotropic Mechanical Property in Plant Cell Walls
Cellulose microfibrils (CMFs) are a major load-bearing component in plant cell walls. Thus, their structures have been studied extensively with spectroscopic and microscopic characterization methods; but the findings from these two approaches were inconsistent, which hampers mechanistic understanding of cell wall mechanics. Here, we report the regiospecific assembly of CMFs in the periclinal wall of plant epidermal cells. Using sum frequency generation spectroscopic imaging, we found that CMFs are highly aligned in the cell edge region where two cells form a junction, whereas they are mostly isotropic on average throughout the wall thickness in the flat face region of the epidermal cell. This subcellular-level heterogeneity in CMF alignment provided insights into tissue-level anisotropy in tensile modulus of cell wall materials. Furthermore, this finding also has resolved a previous contradiction between the spectroscopic and microscopic imaging studies, which paves a foundation for better understanding of cell wall artichecture, especially structure-geometry relationships.
59 BASIC BIOLOGICAL SCIENCES↗
Task Sharing of Proton Incorporation in Vertically Aligned Nanocomposite Triple Conductors: Growth, Structure, and Surface Exchange Kinetics
As protonic ceramic electrolysis cells emerge for efficient H 2 production, there is a need to develop air electrode materials enabling fast, durable steam splitting and proton incorporation. Single-phase triple conductors may fail to satisfy the myriad performance/stability requirements, and their critical charge-carriers (holes, oxygen vacancies, and protons) are in competition, limiting their concentrations. Instead, we propose task-sharing, vertically aligned nanocomposites (VANs), comprising a proton conductor (BaZr 0.9 Y 0.1 O 3-δ ) and a redox-active mixed ionic electronic conductor (Ce 0.9 Pr 0.1 O 2-δ ), that may enable rapid proton surface exchange at the solid–gas interface and transport along the solid–solid heterointerfaces. We grew VANs by pulsed laser deposition and investigated the interplay between their processing conditions, structure, and proton and oxygen surface exchange kinetics. We varied the substrate temperature, laser repetition rate, laser fluence, and processing oxygen pressure. The crystallinity and phases were characterized by grazing-incidence X-ray diffraction, and the strain and structural order as a function of depth were evaluated by angle-dependent synchrotron X-ray pair distribution function analysis. To evaluate the potential for interdiffusion, the formation energies of substitutional defects were simulated with density functional theory. Corresponding structural analysis and elemental mapping were performed by scanning/transmission electron microscopy, energy-dispersive X-ray spectroscopy, and electron energy-loss spectroscopy, indicating distinct nanoscale compositional regions with a hierarchical structure embedded in individual VANs columns and minimal interdiffusion across a bilayer film. Proton and oxygen surface exchange coefficients (k H , k O ) and polarization resistances were evaluated by electrical and optical relaxations and impedance spectroscopy of VAN-incorporated protonic ceramic electrochemical cells, respectively, at 400–500 °C, demonstrating values comparable to some of the best-known triple and mixed conductors.
36 MATERIALS SCIENCE↗
Intrinsic thermal interfacial resistance measurement in bonded metal–polymer foils
Heat conduction through bonded metal–polymer interfaces often limits the overall heat transfer in electronic packaging, batteries, and heat recovery systems. To design the thermal circuit in such systems, it is essential to measure the thermal interfacial resistance (TIR) across ~1 µm to 100 µm junctions. Previously reported TIR of metal–polymer junctions utilize ASTM E1530-based two-block systems that measure the TIR by applying pressure across the interface through external heating and cooling blocks. Here, we report a novel modification of the ASTM-E1530 technique that employs integrated heaters and sensors to provide an intrinsic TIR measurement of an adhesively bonded metal–polymer junction. We design the measurement technique using finite element simulations to either passively suppress or actively compensate the lateral heat diffusion through the polymer, which can minimize the systematic error to ≲5%. Through proof-of-concept experiments, we report the TIR of metal–polymer interfaces made from DuPont’s Pyralux double-side copper-clad laminates, commonly used in flexible printed circuit boards. Our TIR measurement errors are <10%. We highlight additional sources of errors due to non-idealities in the experiment and discuss possible ways to overcome them. Our measurement technique is also applicable to interfaces that are electrically insulating such as adhesively joined metal–metal junctions and sputter-coated or welded metal–polymer junctions. Altogether, the technique is capable of measuring TIR ≳10 –5 m 2 KW –1 in bonded metal–polymer foils and can be tailored for in situ measurements in flexible electronics, circuit packaging, and other hybrid metal–polymer systems.
47 OTHER INSTRUMENTATION↗
Dynamically morphing microchannels in liquid crystal elastomer coatings containing disclinations
Liquid crystal elastomers (LCEs) hold a major promise as a versatile material platform for smart soft coatings, since their orientational order can be predesigned to program a desired dynamic profile. In this work, we introduce temperature-responsive dynamic coatings based on LCEs with arrays of singular defects-disclinations that run parallel to the surface. The disclinations form in response to antagonistic patterns of the molecular orientation at the top and bottom surfaces, imposed by the plasmonic mask photoalignment. Upon heating, an initially flat LCE coating develops linear microchannels located above each disclination. The stimulus that causes a non-flat profile of LCE coatings upon heating is the activation force induced by the gradients of molecular orientation around disclinations. To describe the formation of microchannels and their thermal response, we adopt a Frank-Oseen model of disclinations in patterned director field and propose a linear elasticity theory to connect the complex spatially-varying molecular orientation to the displacements of the LCE. The thermo-responsive surface profiles predicted by the theory and by the finite element modeling are in good agreement with the experimental data; in particular, higher gradients of molecular orientation produce a stronger modulation of the coating profile. The elastic theory and the finite element simulations allow us to estimate the material parameter that characterizes the elastomer coating’s response to the thermal activation. The disclinations containing LCEs show potential as soft dynamic coatings with a predesigned responsive surface profile.
36 MATERIALS SCIENCE↗
Directional shock diode behavior through the interaction of geometric voids in engineered polymer assemblies
With the advent of additive manufacturing (AM) techniques, a new class of shockwave mitigation and structural supports has been realized through the hierarchical assembly of polymer materials. To date, there have been a limited number of studies investigating the role of structure on shockwave localization and whether AM offers a means to tailor shockwave behavior. Of particular interest is whether the mesoscopic structure can be tailored to achieve shockwave properties in one direction of impact vs the other. In this work, we illustrate directional response in engineered polymer foams. In situ time-resolved x-ray phase contrast imaging at the Advanced Photon Source was used to characterize these diode-like structures. This work offers a breakthrough in materials technology for the development of protective structures that require augmentation of shock in one direction while diminishing transmission in the opposite direction.
42 ENGINEERING↗
Time integrator agnostic charge conserving finite element PIC
Developing particle-in-cell (PIC) methods using finite element basis sets, and without auxiliary divergence cleaning methods, was a longstanding problem until recently. It was shown that if consistent spatial basis functions are used, one can indeed create a methodology that was charge conserving, albeit using a leapfrog time stepping method. While this is a significant advance, leapfrog schemes are only conditionally stable and time step sizes are closely tied to the underlying mesh. Ideally, to take full advantage of advances in finite element methods (FEMs), one needs a charge conserving PIC methodology that is agnostic to the time stepping method. This is the principal contribution of this paper. In what follows, we shall develop this methodology, prove that both charge and Gauss’ laws are discretely satisfied at every time step, provide the necessary details to implement this methodology for both the wave equation FEM and Maxwell solver FEM, and finally demonstrate its efficacy on a suite of test problems. The method will be demonstrated by single particle evolution, non-neutral beams with space-charge, and adiabatic expansion of a neutral plasma, where the Debye length has been resolved, and real mass ratios are used.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Thermal conductivity modeling of monodispersed microspheres using discrete element method
Particle beds are widely used in various systems and processes, such as particle heat exchangers, granular flow reactors, and additive manufacturing. Accurate modeling of the thermal conductivity of particle beds and understanding of their heat transfer mechanisms are important. However, previous models were based on simple cubic packing of particles, which could not accurately represent the actual heat transfer processes under certain conditions. Here, we examine the effect of the packing structure on the thermal conductivity of particle beds. We use monodispersed silica microspheres with average particle sizes ranging from 23 to 330 μm as a model material. We employ a transient hot-wire technique to measure the thermal conductivity of the particle beds with packing density of 43%–57% within a temperature range of room temperature to 500 °C and under N2 gaseous pressures of 20–760 Torr. We then use a discrete element method (DEM) to obtain the realistic packing structure of the particles, which is then fed into a finite-element model (FEM) to calculate the thermal conductivity, with the consideration of solid conduction, gas conduction, and radiation heat transfer. Our results show that the thermal conductivity model based on the more realistic random packing structure derived from the DEM shows better agreement with the experimental data compared to that based on the simple cubic-packing structure. The combined DEM and FEM methodology can serve as a useful tool to predict the effective thermal conductivity of particle beds and to quantify different heat transfer mechanisms under various conditions.
14 SOLAR ENERGY↗
A semi-analytical model for laser induced densification in fused silica at elevated temperatures
A semi-analytical model for deterministic surface smoothing of fused silica below the evaporation temperature threshold is presented. Using this model, a method for calculating deterministic track depths for laser polishing fused silica is derived and validated with experiments. In this work, model predictions were in good agreement with experiment across varying laser preheating temperature and power. With the semi-analytical method presented here, deterministic laser smoothing can be achieved in the densification regime to close the process loop of laser polishing.
36 MATERIALS SCIENCE↗