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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Rafting-Enabled Recovery Avoids Recrystallization in 3D-Printing-Repaired Single-Crystal Superalloys

The repair of damaged Ni-based superalloy single-crystal turbine blades has been a long-standing challenge. Additive manufacturing by an electron beam is promising to this end, but there is a formidable obstacle: either the residual stress and γ/γ' microstructure in the single-crystalline fusion zone after e-beam melting are unacceptable (e.g., prone to cracking), or, after solutionizing heat treatment, recrystallization occurs, bringing forth new grains that degrade the high-temperature creep properties. Here, a post-3D printing recovery protocol is designed that eliminates the driving force for recrystallization, namely, the stored energy associated with the high retained dislocation density, prior to standard solution treatment and aging. The post-electron-beam-melting, pre-solutionizing recovery via sub-solvus annealing is rendered possible by the rafting (i.e., directional coarsening) of γ' particles that facilitates dislocation rearrangement and annihilation. The rafted microstructure is removed in subsequent solution treatment, leaving behind a damage-free and residual-stress-free single crystal with uniform γ' precipitates indistinguishable from the rest of the turbine blade. Finally, this discovery offers a practical means to keep 3D-printed single crystals from cracking due to unrelieved residual stress, or stress-relieved but recrystallizing into a polycrystalline microstructure, paving the way for additive manufacturing to repair, restore, and reshape any superalloy single-crystal product.

36 MATERIALS SCIENCE↗
NASA NTRS2003

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

Surface enhancement technologies such as shot peening, laser shock peening (LSP), and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The X-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including: * The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing fatigue benefit of thermal stability at engine temperatures. * An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. * Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. * Corrosion fatigue mitigation with LPB in Carpenter 450 steel. *Damage tolerance improvement in 17-4PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.

Prevey, Paul S.↗
NASA NTRS1979

Some properties of an advanced boron fiber

An advanced coreless boron fiber exhibits tensile strengths which are more than twice that of the normal CVD B/W fibers. The coreless fiber is made by the chemical removal of the tungsten boride core exposed by splitting the as-grown fiber. The easily splittable fiber is made by the chemical vapor deposition of boron on a larger than usual tungsten substrate. It is expected that the ease of splitting is related to residual stresses in these fibers. Measurements of the axial residual stresses in both the normal and the splittable fibers are presented and the results compared. Differences in these stresses are discussed in connection with the ease of splitting in the splittable fibers.

Behrendt, D. R.↗
NASA NTRS1979

Some properties of an advanced boron fiber

An advanced coreless boron fiber has exhibited tensile strengths which are more than twice that of the normal CVD B/W fibers. The coreless fiber is made by the chemical removal of the tungsten boride core exposed by splitting the as-grown fiber. The easily splittable fiber is made by the chemical vapor deposition of boron on a larger than usual tungsten substrate. It is expected that the ease of splitting is related to residual stresses in these fibers. Measurements of the axial residual stresses in both the normal and the splittable fibers are presented and the results compared. Differences in these stresses are discussed in connection with the ease of splitting in the splittable fibers.

Behrendt, D. R.↗
NASA NTRSDate not supplied

Effect of Boundary Conditions on Process-Induced Stresses in a Plain Weave Unit Cell

Woven polymer matrix composites (PMCs) are leveraged in aerospace applications for their desirable specific properties, yet they are vulnerable to high residual stresses during manufacturing and their complex geometry makes experimental results difficult to observe. Process modeling is needed to characterize the effects of the curing and predict end stress states. Finite element software can be used to model woven architectures, however accurate representation of processing conditions remains a challenge when it comes to selecting boundary conditions. The effect of BCs on process-induced stress within woven PMCs is studied. The commercial Finite Element Analysis (FEA) software Abaqus is coupled with user-written subroutines in a process modeling framework. A two-dimensionally (2D) woven PMC repeating unit cell (RUC) is modeled with TexGen and Abaqus. Virtual curing is imposed on the bulk matrix. The BC study is conducted with Free, Periodic, Flat, and Flat-Free configurations. Results show that the end stress state is sensitive to the boundary condition assumptions. Flat BC results show great agreement with Periodic BCs. Residual stress results from process modeling are then compared with a linear-elastic thermal cooldown analysis in Abaqus. Cooldown results indicate an overestimation in matrix stresses compared with process modeling.

micromechanics↗
DOE OSTI2018

Advanced manufacturing—A transformative enabling capability for fusion

Additive Manufacturing (AM) can create novel and complex engineered material structures. Features such as controlled porosity, micro-fibers and/or nano-particles, transitions in materials and integral robust coatings can be important in developing solutions for fusion subcomponents. A realistic understanding of this capability would be particularly valuable in identifying development paths. Major concerns for using AM processes with lasers or electron beams that melt powder to make refractory parts are the power required and residual stresses arising in fabrication. A related issue is the required combination of lasers or e-beams to continue heating of deposited material (to reduce stresses) and to deposit new material at a reasonable built rate while providing adequate surface finish and resolution for meso-scale features. Some Direct Write processes that can make suitable preforms and be cured to an acceptable density may offer another approach for PFCs.

Additive Manufacturing, fusion energy, Fusion Mate↗
NASA NTRS1994

Analysis of cold worked holes for structural life extension

Cold working holes for improved fatigue life of fastener holes are widely used on aircraft. This paper presents methods used by the authors to determine the percent of cold working to be applied and to analyze fatigue crack growth of cold worked fastener holes. An elastic, perfectly-plastic analysis of a thick-walled tube is used to determine the stress field during the cold working process and the residual stress field after the process is completed. The results of the elastic/plastic analysis are used to determine the amount of cold working to apply to a hole. The residual stress field is then used to perform damage tolerance analysis of a crack growing out of a cold worked fastener hole. This analysis method is easily implemented in existing crack growth computer codes so that the cold worked holes can be used to extend the structural life of aircraft. Analytical results are compared to test data where appropriate.

Wieland, David H.↗
DOE OSTI2019

Interfacial Strength Evaluation of Oxide Films on Carbon Steel by Using the Laser Shock Adhesion Test

We investigate the adhesion strength (interfacial strength) of the oxide film formed on a carbon steel substrate by using a laser shock adhesion test (LaSAT). A rolled carbon steel (SS400) plate is first heated at high temperature (700 °C) under the atmosphere (heat treatment) to cause the formation of oxide films about 20-50 μm thick on the steel surface. The film consisted of multiple layers, including wustite (FeO), magnetite (Fe{sub 3}O{sub 4}), and hematite (Fe{sub 2}O{sub 3}). Next, the x-ray diffraction method was used to measure the residual stress in the film. We find that compression stress develops in the film because of a mismatch of thermal strain in between the film and substrate after the heat treatment. With LaSAT, strong elastic wave generates by a pulsed laser ablation of the substrate backside, and results in interfacial fractures in the oxide films. To monitor the normal (out-of-plane) displacement of the top surface film, a laser ultrasonic interferometer is simultaneously utilized, such that we detect film delamination and determine the critical laser energy for interfacial fracture to obtain the critical stress (interfacial strength). Furthermore, additional pulsed laser irradiation is conducted against a pre-delaminated specimen in order to examine the growth of delamination area and evaluate the interfacial fracture toughness. Finally, elastic wave propagation in the sample is computed using the finite element method (FEM) in order to evaluate the interfacial stress field, accurately. For the FEM, multiple layers in the oxide film are modeled, and the residual stress due to thermal strain mismatch is introduced. The FEM computations reveal the stress distribution around the interface and evaluate the critical stress and critical stress intensity factor for delamination. We thus quantitatively evaluate the interfacial strength and interfacial fracture toughness of the oxide film formed on carbon steel. The mechanism of interfacial fracture is also discussed on the basis of microstructures in a film with multiple layers. This result may be useful for understanding the adhesion quality of oxide film during the hot-rolling process.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Thermomechanical behavior of plasma-sprayed ZrO2-Y2O3 coatings influenced by plasticity, creep and oxidation

Thermocycling of ceramic-coated turbomachine components produces high thermomechanical stresses that are mitigated by plasticity and creep but aggravated by oxidation, with residual stresses exacerbated by all three. These residual stresses, coupled with the thermocyclic loading, lead to high compressive stresses that cause the coating to spall. A ceramic-coated gas path seal is modeled with consideration given to creep, plasticity, and oxidation. The resulting stresses and possible failure modes are discussed.

Padovan, J.↗
NASA NTRS1987

Thermomechanical behavior of plasma-sprayed ZrO2-Y2O3 coatings influenced by plasticity, creep, and oxidation

Thermocycling of ceramic-coated turbomachine components produces high thermomechanical stresses that are mitigated by plasticity and creep but aggravated by oxidation, with residual stresses exacerbated by all three. These residual stresses, coupled with the thermocyclic loading, lead to high compressive stresses that cause the coating to spall. A ceramic-coated gas path seal is modeled with consideration given to creep, plasticity, and oxidation. The resulting stresses and possible failure modes are discussed.

Padovan, J.↗
DOE OSTI2021

A coupled fluid-mechanical workflow to simulate the directed energy deposition additive manufacturing process

Simulation of additive manufacturing processes can provide essential insight into material behavior, residual stress, and ultimately, the performance of additively manufactured parts. In this work, we describe a new simulation based workflow utilizing both solid mechanics and fluid mechanics based formulations within the finite element software package SIERRA (Sierra Solid Mechanics Team in Sierra/Solid Mechanics 4.52 User’s Guide SAND2019-2715. Technical report, Sandia National Laboratories, 2011) to enable integrated simulations of directed energy deposition (DED) additive manufacturing processes. In this methodology, a high-fidelity fluid mechanics based model of additive manufacturing is employed as the first step in a simulation workflow. This fluid model uses a level set field to track the location of the boundary between the solid material and background gas and precisely predicts temperatures and material deposition shapes from additive manufacturing process parameters. Next, the resulting deposition shape and temperature field from the fluid model are then mapped into a solid mechanics formulation to provide a more accurate surface topology for radiation and convection boundary conditions and a prescribed temperature field. Solid mechanics simulations are then conducted to predict the evolution of material stresses and microstructure within a part. By combining thermal history and deposition shape from fluid mechanics with residual stress and material property evolutions from solid mechanics, additional fidelity and precision are incorporated into additive manufacturing process simulations providing new insight into complex DED builds.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Two-step polarization reversal in biased ferroelectrics

Polarization reversal in polycrystalline ferroelectrics is shown to occur via two distinct and sequential domain reorientation steps. This reorientation sequence, which cannot be readily discriminated in the overall sample polarization, is made apparent using time-resolved high-energy x-ray diffraction. Upon application of electric fields opposite to the initial poling direction, two unique and significantly different time constants are observed. The first (faster time constant) is shown to be derived by the release of a residual stress due to initial electrical biasing and the second (slower time constant) due to the redevelopment of residual stress during further domain wall motion. A modified domain reorientation model is given that accurately describes the domain volume fraction evolution during the reversal process.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Microstructure and hot corrosion behavior of the Ni-based superalloy GH202 treated by laser shock processing

The effects of laser shock processing on microstructure, the residual stress, and hot corrosion behavior of the Ni-based superalloy GH202 were investigated. The microstructures of GH202 before and after laser shock processing (LSP) were characterized by electron backscattered diffraction (EBSD) and transmission electron microscope (TEM). A large number of crystal defects (twins, dislocation arrays, and high dense tangles) were generated on the surface of GH202 treated with LSP. The cross-sectional compressive residual stress and micro-hardness of specimens treated by LSP were improved significantly. The corrosion kinetics of GH202 with or without LSP treatment at 800 °C and 900 °C were investigated. Analysis by X-ray diffraction (XRD) revealed that the corrosion products mainly consist of Cr{sub 2}O{sub 3}, TiO{sub 2}, Al{sub 2}O{sub 3}, NiO, CrS, Ni{sub 3}S{sub 2}, and Na{sub 2}CrO{sub 4}. The surface and cross-section morphologies were observed by scanning electron microscope (SEM) combined with energy dispersive spectroscopy (EDS). The results confirmed that the crystal defects induced by LSP promotes the creation of diffusion paths for elements (Cr, Al, and Ti), allowing the formation of tiny homogeneous oxidation films in a very short time. Additionally, the spallation of oxidation film on the treated specimens was alleviated significantly. Overall, the hot corrosion resistance of Ni-based GH202 induced by LSP was improved in Na{sub 2}SO{sub 4} and NaCl molten salt from 800 °C to 900 °C. - Highlights: • Microstructure changes of GH202 before and after LSP were observed by EBSD and TEM. • The hardness and residual compressive stress after LSP were significantly increased. • The increased diffusion paths for elements helped to form oxidation films quickly. • Hot corrosion resistance of GH202 after LSP was significantly improved.

36 MATERIALS SCIENCE↗
NASA NTRS2015

Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

Fatigue↗
DOE OSTI2016

Estimating the Penetration Depth and Orientation of Stress Corrosion Cracks Using Time-Reversal Acoustics

Austenitic stainless steels are known to be susceptible to stress corrosion cracking (SCC), which is an aggressive type of corrosion that exists when a material under tensile stress is placed in a corrosive environment. This is of particular concern as the processing (i.e., cold rolling) and construction (welding) of storage canisters produce an inherent residual stress in metals that can lead to SCC. In this context, our objective is to study the formation of stress corrosion cracks within Type 304L stainless steel, which is frequently used in containers for used nuclear fuel disposal. The conditions present in storage canisters (i.e., elevated temperatures, high residual stresses near welds, and exposure to humidity and chloride) make them susceptible to SCC, potentially leading to critical through-wall failure, and thus loss of containment. The timescales on which through-wall failure is expected in a storage canister under typical conditions is on the order of tens of years. While through-wall flaws are catastrophic (e.g., release of helium and fission gases), the long timescales allow for routine inspection, and potentially mitigation, providing methods exist. This paper is focused on the former problem, i.e. detection of SCC, and the development of a tool for inspection of storage canisters. We will discuss the recent work we did on detecting the presence of SCC as well as imaging on its orientation and penetration depth using an acoustic technique developed at Los Alamos National Laboratory (LANL). This technique has been applied successfully in the laboratory on stainless steel samples with SCC provided by General Electric (GE) and the Electric Power Research Institute (EPRI). Recently, we have also demonstrated that this technique can be deployed for field inspections in tight and confined spaces. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Crack Growth Rate and Large Plate Demonstration of Chloride-induced Stress Corrosion Cracking in Spent Nuclear Fuel Storage Canisters

This report describes the body of work involving testing and analyses performed in FY18 and FY19 at the Savannah River National Laboratory and at Korea University to determine chloride-induced stress corrosion crack (CISCC) growth rates in weldments of austenitic stainless steel plate material. The primary work involved: several separate crack growth rate test campaigns with new testing setups using laboratory-scale corrosion specimens; analyses to estimate the stress intensity factors for flaws postulated to be present in the residual stress fields of axial and circumferential weldments in a prototypic dry storage canister; and establishment of a “large plate” (approximately 51×46 cm with thickness 16 mm and weight about 30 kg) CISCC test that uses a plate with a circumferential weldment harvested from the Sandia National Laboratories’ full-size mockup dry storage canister. The tests for crack growth rate were conducted on ASTM E1861 bolt-load compact tension specimens in a setup designed to allow initially dried salt deposits to deliquesce and infuse the brine to the crack front under conditions relevant to the canister storage environments (e.g., temperature and humidity). The crack growth rate test results matched previous experimental data in the open literature. These literature data had been compiled by SNL and EPRI to develop a temperature-dependent (K-insensitive) crack growth rate model to support flaw disposition in the ASME Boiler and Pressure Vessel Section XI Code Case N-860, “Examination Requirements and Acceptance Standards for Spent Nuclear Fuel Storage and Transportation Containment Systems.” The knowledge of the salt, temperature, humidity conditions for CISCC including the threshold stress intensity factor, $K_{ISCC}$, were used to setup the large plate test in which a set of partthrough- wall and through-wall electrical discharge machined (EDM) defects were positioned in the weld residual stress field of the welded plate material from the mockup canister. A salt solution was applied to this plate specimen with an air-brush spray, then dried, and then exposed to a constant 75% RH condition at an ambient room temperature of 22 °C. The salt loading and environmental condition is expected to be aggressive to cause CISCC. The visual results at the surface of the plate show corrosion product staining (brown rust appearance) but with no CISCC emanating from the machined notches after approximately 5 months exposure to date. The plate test will continue in FY20 and phased-array ultrasonic testing and other NDE techniques will be applied to identify and characterize CISCC that may emanate from the machined defects. The notches and any CISCC from them will be sectioned at the conclusion of the test to verify NDE characterization, and to develop effective through-wall crack growth rates from cracks that would likely be branched.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Engineering Stress in Perovskite Solar Cells to Improve Stability

We report on an overlooked factor affecting stability: the residual stresses in perovskite films, which are tensile and can exceed 50 MPa in magnitude, a value high enough to deform copper. These stresses provide a significant driving force for fracture. Films are demonstrated to be more unstable under tensile stress—and conversely more stable under compressive stress— when exposed to heat or humidity. Increasing the formation temperature of perovskite films directly correlates with larger residual stresses, a result of the high thermal expansion coefficient of perovskites. Specifically, this tensile stress forms upon cooling to room temperature, as the substrate constrains the perovskite from shrinking. No evidence of stress relaxation is observed, with the purely elastic film stress attributed to the thermal expansion mismatch between the perovskite and substrate. Additionally, the authors demonstrate that using a bath conversion method to form the perovskite film at room temperature leads to low stress values that are unaffected by further annealing, indicating complete perovskite formation prior to annealing. It is concluded that reducing the film stress is a novel approach for improving perovskite stability, which can be accomplished by lower formation temperatures, flexible substrates with high thermal expansion coefficients, and externally applied compressive stress after fabrication.

36 MATERIALS SCIENCE↗
NASA NTRS1973

Theoretical and experimental investigation of the nonlinear behavior of angleplied boron/aluminum composites

Specimens from angleplied laminates of boron/aluminum composites were tested and the results analyzed. The specimens consisted of eight-ply symmetric layups and were loaded in tension at various angles to the 0 deg-ply direction. Stress-strain curves to specimen fracture were obtained. The analysis was performed using linear composite mechanics which includes residual stresses and a combined stress yield function. The results obtained indicate that angleplied boron/aluminum laminates exhibit a nonlinear stress-strain behavior to fracture. The residual stresses affect the initial and yield laminate properties. Linear composite mechanics is inadequate to predict the mechanical behavior of boron/aluminum angleplied laminates.

Chamis, C. C.↗