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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Lifetime estimation of a BWR core shroud in terms of IGSCC

The continued operation of aging Boiling Water Reactors (BWRs) worldwide requires gradually increasing cost of inspection, maintenance, and repair. Intergranular Stress Corrosion Cracking (IGSCC) in sensitized austenitic stainless steel piping first became a major issue for BWRs in the 1980s, resulting in recognition of the susceptibility of reactor internals to IGSCC. Shroud cracking identified in 1993–1994 confirmed that IGSCC of internals is a significant issue for BWRs. IGSCC is a time-dependent, material degradation process, which is caused and accelerated by the presence of residual stresses, material sensitization, irradiation, cold work, elevated temperature, and corrosive environments. This paper emphasizes the importance of accounting for corrosive environments, or more exactly, electrochemical phenomena in modelling IGSCC and predicting the service life of BWR in-vessel components, and stresses the necessity of performing such modeling not just for a single state point under full power conditions, but for the whole operating history of the reactor, including startups and shutdowns. Overall, this paper demonstrates that ignoring electrochemical considerations may result in underestimating component lifetime and lead to unnecessary expenses for inspection and repair.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Compression behavior of microcrystalline cellulose spheres: Single particle compression and confined bulk compression across regimes

Particle characteristics can drastically influence the process-structure-property-performance aspects of granular materials in compression. In this study, we aim to computationally simulate the mechanical processes of stress redistribution in compacts including the kinematics of particle rearrangement during densification and particle deformation leading to fragmentation. Confined compression experiments are conducted with three sets of commercial microcrystalline cellulose particles nearly spherical in shape with different mean particle size. Experimentally measured compression curves from tall powder columns are fitted with the Kenkre et al. (J. of American Chemical Society, Vol. 79, No. 12) model. This model provides a basis to derive several common two-parameter literature models and as a framework to incorporate statistical representations of critical particle behaviors. We focus on the low-stress compression data and the model comparisons typically not discussed in the literature. Furthermore, additional single particle compressions report fracture strength with particle size for comparison to the apparent particle strength extracted from bulk compression data.

42 ENGINEERING↗
DOE OSTI2021

Analyzing Mechanical integrity of Microwave resonant Cavity flowmeter

The microwave resonant cavity flow sensor has been proposed to address the difficulties of measuring high-temperature molten salt flow in reactor vessels. The flow sensor consists of a metallic cylindrical cavity coupled to a microwave waveguide. The cylindrical cavity has one of the flat surfaces thin enough to undergo microscopic deflection due to dynamic pressure of the exerted by the flowing fluid. Deflection of the membrane causes a shift in the microwave resonant frequency. Fluid velocity can be estimated from the calibration curve. The objective of this report is to investigate mechanical integrity of the flowmeter’s membrane. The membrane is a thin stainless-steel circular plate with a clamped edge, subjected to uniform load. By calculating the stress on the plate due to deflection and, comparing the stress to the material ultimate tensile strength and yield strength, it can be estimated if the plate will fail. If the maximum stress is greater than the yield strength, the plate will undergo plastic deformation, and the sensor will be disabled. A stress greater than the ultimate tensile strength will cause the plate to fracture. The stress on the plate was calculated with an analytic closed form solution model, and with COMSOL Structural Mechanics Module which does not involve any approximations. Stresses in both the analytic model and COMSOL numerical model were calculated for stainless steel 316 thin circular plates under room temperature conditions, where the fluid is water. The diameter of the circular plate is approximately one inch, and thickness is 10mil. Fluid flow velocity is in the range from 0.5m/s to 1m/s. The results from the two models are similar. Both the analytic model and COMSOL model showed that maximum stresses on the plate, which are at the radial boundary of the plate, are three orders of magnitude smaller than the yield strength and ultimate tensile strength. This indicates that the sensor is at a low risk of mechanical failure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

CVEN 5899 Internship report

The internship is under the project of Center for Space and Earth Science student fellow program of Los Alamos National Laboratory (LANL). The topic of the project is grain-scale prediction of hypervelocity projectile penetration into terrestrial and extraterrestrial granular materials, which is also my PhD research topic. In this research, we would like to use discrete element method (DEM) to simulate the hyper-speed penetration into granular materials and compare with experiment results. The experiment is done by the Proton Radiography (pRad) team of LANL. In the experiment, a jet traveled through the sand with velocity of 4 km/s (fig.1). Our goal is to develop the large deformation constitutive model by the stress and strain upscaling, study the fluid (air) behavior and particle fracture during the hyperspeed penetration.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturers (OEM)s. In addition to high strength for safety requirements, superior Self Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight and thus improving energy efficiency. The purpose of this project is to extend and validate an existing f

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2021

3D orthorhombic earth model effects on seismic source characterization

Most earth materials are anisotropic with regard to seismic wave-speeds, especially materials such as shales, or where oriented fractures are present. However, the base assumption for many numerical simulations is to treat earth materials as isotropic media. This is done for simplicity, the apparent weakness of anisotropy in the far field, and the lack of well-characterized anisotropic material properties for input into numerical simulations. One approach for addressing the higher complexity of actual geologic regions is to model the material as an orthorhombic medium. We have developed an explicit time-domain, finite-difference (FD) algorithm for simulating three-dimensional (3D) elastic wave propagation in a heterogeneous orthorhombic medium. The objective of this research is to investigate the errors and biases that result from modeling a non-isotropic medium as an isotropic medium. This is done by computing “observed data” by using synthetic, anisotropic simulations with the assumption of an orthorhombic, anisotropic earth model. Green’s functions for an assumed isotropic earth model are computed and then used an inversion designed to estimate moment tensors with the “observed” data. One specific area of interest is how shear waves, which are introduced in an anisotropic model even for an isotropic explosion, affect the characterization of seismic sources when isotropic earth assumptions are made. This work is done in support of the modeling component of the Source Physics Experiment (SPE), a series of underground chemical explosions at the Nevada National Security Site (NNSS).

58 GEOSCIENCES↗
DOE OSTI2022

Atomistic Materials Modeling of High-Pressure Hydrogen Interactions in Ethylene Propylene Diene Monomer (EPDM) Rubber

Elastomeric rubbers serve a vital role as sealing materials in the hydrogen storage and transport infrastructure. With applications including O-rings and hose-liners, these components are exposed to pressurized hydrogen at a range of temperatures, cycling rates, and pressure extremes. Cyclic (de)pressurization is known to degrade these materials through the process of cavitation. This readily visible failure mode occurs as a fracture or rupture of the material and is due to the oversaturated gas localizing to form gas bubbles. Computational modeling in the Hydrogen Materials Compatibility Program (H-Mat), co-led by Sandia National Laboratories and Pacific Northwest National Laboratory, employs multi-scale simulation efforts to build a predictive understanding of hydrogen-induced damage in materials. Modeling efforts within the project aim to provide insight into how to formulate materials that are less sensitive to high-pressure hydrogen-induced failure. In this document, we summarize results from atomistic molecular dynamics simulations, which make predictive assessments of the effects of compositional variations in the commonly used elastomer, ethylene propylene diene monomer (EPDM).

08 HYDROGEN↗
DOE OSTI2023

Laboratory Experiments Examining the Effect of Thermal and Mechanical Processes on Hydraulic Transmissivity Evolution

Using laboratory slide-hold-slide experiments, at temperatures from 22 to 200 degrees C, to examine effects of fracture reactivation and quasi-static loading on the evolution of fluid transport properties of simulated fractures in Westerly granite. At all temperatures, the in-plane hydraulic transmissivity consistently decays during hold periods resulting in an overall reduction in transmissivity. During the first three to fifteen hours of an experiment, transmissivity decreases rapidly due to the generation of wear products, development of a sliding surface, and compaction of the resulting gouge. Once the sliding surface has developed, the long-term transmissivity decay rate at 22 and 100 degrees C is significantly lower than the transmissivity decay rate during the initial 3-15 hours of the experiment. However, at 200 degrees C, the decay of hydraulic transmissivity remains high throughout the experiment. The long-term decay of hydraulic transmissivity can be fitted with a power law model with more rapid reduction of hydraulic transmissivity at higher temperature. Periods of sliding on the fracture surface result in transient increases in the transmissivity, due to shear dilation, as is expected for Coulomb materials. These transients are superimposed on the long-term decay. When sliding ceases and a new hold period commences, there is a rapid reduction in transmissivity and return to the long-term rate of transmissivity decay. The rate of decay of the transmissivity transients is inversely correlated with temperature, in contrast to the long-term decay and the expected behavior for processes like subcritical crack growth and indentation creep. The higher decay rates that are observed during the initial 3-15 hours of the tests and following sliding, are associated with times that the porosity of the gouge is expected to be high. The difference in decay rates suggests that when the gouge is driven far from equilibrium by active shearing, densification may be dominated by a different mechanism from long-term compaction.

15 GEOTHERMAL ENERGY↗
DOE OSTI2020

Helium Bubble Growth and Retention Characteristics in Aging Palladium Tritide

The helium-related characteristics of aged palladium tritide, including tritium loss, the formation of He bubbles from tritium decay-induced He atoms, and He thermal desorption behavior are computed using a continuum model of bubble evolution that incorporates the log-normal bubble spacing distribution deduced from 3 He nuclear magnetic resonance (NMR) measurements. This spacing distribution produces significant differences between mean (expectation) values of the bubble size and pressure and the average (median) values of these aging characteristics obtained by a previous calculation. The new calculations find much of the He is retained in a large quantity of smaller bubbles with higher bubble pressures, improving the overall stability of the bubbles and extending the age of He retention. By contrast, the integrated tritide material characteristics of swelling and tritium pressure are found relatively insensitive to details of the bubble spacing distribution. Inter-bubble fracture is predicted to begin with small, closely-spaced bubbles and progress to include larger bubbles near the onset of rapid He release. The critical concentration for this onset increases almost linearly with material tensile strength and decreases with shear modulus. Release of He from the aging solid is modeled as a growing network of fractured inter-bubble ligaments. For small particle or small grain material, the physical size of the fracture cluster, relative to the material dimensions, becomes important. In contrast with normal aging, inter-bubble fracture occurring during thermal desorption appears to begin with large, widely-spaced bubbles, indicating elevated temperature techniques may be of limited use for evaluating development of the bubble fracture network.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2026

An Anisotropic Yield and Damage Material Model to Improve the Contact Pressure Analysis in a Biomass Shredding System

Size reduction systems used in biomass processing break biomass into smaller pieces by utilizing the kinetic energy from the sharp rotating blades. Abrasive and/or erosive wear caused by biomass comminution results in blade wear of the sharp edged cutters, deteriorating the process efficiency. Here, this study aims to optimize the blade design and improve the system efficiency by attempting to understand the interactions between the blades and biomass particles. Since real-time monitoring of these interactions is impractical during operation, mechanical simulations offer a viable alternative for investigating the shredding process. Yet, the irregular geometry and complex mechanical properties of biomass—such as the anisotropic nature of woodchips and their nonlinear fracture behavior—pose significant challenges for accurately simulating contact pressure. In this work an anisotropic yield material model, along with a damage initiation and evolution function, is applied to the woodchip particle to study the contact pressure on shredder blade, offering a scientific basis for improved blade design and process efficiency. This approach can be extended to other biomass processing systems with similar anisotropic feedstocks, making it a valuable tool for advancing sustainable biomass utilization.

09 - BIOMASS FUELS↗
DOE OSTI2020

Sensitivity and history match analysis of a carbon dioxide “huff-and-puff” injection test in a horizontal shale gas well in Tennessee

Due to improvements in well development, shale gas production has gained importance recently, especially in the United States. To improve gas production and develop a better understanding of shale reservoirs, researchers are conducting field tests to monitor CO 2 storage and enhanced gas recovery. Reservoir simulations can then utilize these field results for sensitivity studies, uncertainty analysis, history matching, gas production forecasts, and CO 2 storage capacity estimations. One such field test was performed for the Chattanooga Shale formation in Morgan County, Tennessee. Approximately 463 tonnes (510 tons) of CO 2 was successfully injected into a hydraulically fractured horizontal well over a thirteen-day period in March 2014. The injection test was achieved in four steps: pre-injection, injection, soaking, and flowback. In this paper, those steps were modeled with a reservoir simulator to match the historic production and injection rates with gas component compositions and forecast the production for five years. The reservoir fluid was modeled as a multi-component gas, including CH 4 , C 2 H 6 , C 3 H 8 , N 2 , and CO 2 . Langmuir constants, reservoir pressure, and fracture network volume were adjusted to match simulation results with observed production rates and gas composition. Results showed that, under the same reservoir conditions, each gas component behaves differently by way of compositional changes in production. CH4 behaves like N2, while CO 2 behaves like heavier hydrocarbons such as C 2 H 6 and C 3 H 8 . CO 2 plume results showed that, after injection, the produced CO 2 is mostly derived from fractured limestone (i.e., Fort Payne Formation) because the injected CO 2 is not adsorbed in limestone but rather by shale formations.

03 NATURAL GAS↗
DOE OSTI2024

Groundwater and Surface Water Flow (GSFLOW) model files to explore bedrock circulation depth and porosity in Copper Creek, Colorado

This data package contains integrated hydrological model input and output files for Copper Creek, Colorado (24 km2), a tributary of the East River located in the headwaters of the Upper Colorado River Basin. The model code is the U.S. Geological Survey (USGS) Groundwater and Surface Water Flow (GSFLOW) model. The model contains a 100-m grid resolution and a daily timestep. The land surface model is dynamically linked to a three-dimensional groundwater flow model that allows for streamflow gaining and losing conditions. The groundwater model contains 12 model layers and extends 400 m below land surface. The original Copper Creek model was modified to contain geologic layers representing saprolite, shallow bedrock, and deep bedrock. Endmember depth versus hydraulic conductivity relationships and porosity values for fractured crystalline rock are simulated. For the shallow case, median flow depths occur in the shallow saprolite at depths <8 m, while the deep case promotes a median groundwater flow depth of 100 m. With this modeling framework we compare streamflow response to a plausible worst-case drought lasting up to five years. Streamflow metrics of analysis include average streamflow, fraction of stream network that is dry, no-flow duration, average groundwater flow to streams and time to recovery following the drought. Results and implications are presented in a paper submitted to Geophysical Research Letters titled, "The role of bedrock circulation depth and porosity in mountain streamflow response to prolonged drought" by Rosemary WH. Carroll, Andrew H. Manning and Kenneth H Williams. A Readme.txt file provides instructions on how to download all model files and execute each model scenario. In addition to the GSFLOW output/prms/copper_drought.csv file containing daily basin water stores and fluxes (refer to GSFLOW manual) and the output/prms/copper_drought_statvar.dat file with output defined in the gsflow3.control file (refer to GSFLOW Manual), output files also include spatially distributed daily values of total evapotranspiration, canopy evaporation, precipitation, snowfall, infiltration, snow water equivalent, potential evapotranspiration, recharge, sublimation, soil moisture, contributing interflow, water table elevations, changes in groundwater storage, groundwater evapotranspiration, interbasin groundwater flow (limited to the alluvium below the stream outlet), and surface-groundwater exchanges within the river system.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Assessment of buffer-IPyC thermomechanical debonding behavior using new experimental strength data in BISON

TRIstructural ISOtropic (TRISO) fuel is a nuclear fuel commonly used in High Temperature Gas-cooled Reactors (HTGRs). A single sub-millimeter-diameter TRISO fuel particle consists of a spherical fuel kernel surrounded by four coating layers: a low-density pyrocarbon buffer layer, an inner pyrolytic carbon (IPyC) layer, a silicon carbide (SiC) layer, and an outer pyrolytic carbon (OPyC) layer. The kernel is commonly made of UO2 or a mixture of uranium carbide and uranium oxide (UCO). During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. Not all irradiated particles will experience buffer-IPyC gap formation. The debonding may be partial, or it may be nearly total. However, from post-irradiation examination of UCO TRISO fuels irradiated as part of the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program, it was concluded that partial buffer-IPyC debonding was the most common type of buffer-IPyC interaction. To predict TRISO thermomechanical performance, multi-physics models have been built that are being continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for 1D, 2D, and 3D TRISO particle simulations. This code is used to calculate fuel temperature, kernel swelling, buffer densification, thermal and irradiation creep, fracture, and fission gas production and release. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated AGR TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. That observation is also implemented in the TRISO interface debonding model. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

GeoThermalCloud for EGS – An Open-source, User-friendly, Scalable AI Workflow for Modeling Enhanced Geothermal Systems

Enhanced Geothermal Systems (EGS) offer a vast potential to expand the use of geothermal energy. Heat is extracted from this engineered system by injecting relatively cold water into subsurface fractures, which are in contact with hot dry rock, and brought back to surface through production wells. Creating EGS requires improving the natural permeability of hot crystalline rocks. In this short conference paper, we present a reproducible workflow for modeling EGS. Our workflow called the GeoThermalCloud (GTC) for EGS, leverages recent advances in machine learning, deep learning, and high-performance computing. This GTC framework is currently being made open-source, user-friendly, and reproducible through python scripts as well as Google Colab/Jupyter Notebooks. This GTC for EGS modeling scripts are made available at https://github.com/SmartTensors/GeoThermalCloud.jl/tree/master/EGS and will constantly be updated to cater for geothermal community. Current GTC framework provides scripts to train deep learning (DL) models for techno-economics and data worth analysis. The Geothermal Design Tool (https://github.com/GeoDesignTool/GeoDT.git), a fast and simplified multi-physics solver, is used to develop a database for training DL models. This short paper provides details on the scripts to curate, process, and train DL models. The scripts can easily be modified to train on databases generated by other popular open-source simulators such as PFLOTRAN, STOMP, TOUGH, and GEOSX or commercial software such as ResFrac and COMSOL.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Artificial neural network potentials for mechanics and fracture dynamics of two-dimensional crystals **

Understanding the mechanics and failure of materials at the nanoscale is critical for their engineering and applications. The accurate atomistic modeling of brittle failure with crack propagation in covalent crystals requires a quantum mechanics-based description of individual bond-breaking events. Artificial neural network potentials (NNPs) have emerged to overcome the traditional, physics-based modeling tradeoff between accuracy and accessible time and length scales. Previous studies have shown successful applications of NNPs for describing the structure and dynamics of molecular systems and amorphous or liquid phases of materials. However, their application to deformation and failure processes in materials is still uncommon. In this study, we discuss the apparent limitations of NNPs for the description of deformation and fracture under loadings and propose a way to generate and select training data for their employment in simulations of deformation and fracture simulations of crystals. We applied the proposed approach to 2D crystalline graphene, utilizing the density-functional tight-binding method for more efficient and extensive data generation in place of density functional theory. Then, we explored how the data selection affects the accuracy of the developed artificial NNPs. It revealed that NNP’s reliability should not only be measured based on the total energy and atomic force comparisons for reference structures but also utilize comparisons for physical properties, e.g. stress–strain curves and geometric deformation. In sharp contrast to popular reactive bond order potentials, our optimized NNP predicts straight crack propagation in graphene along both armchair and zigzag (ZZ) lattice directions, as well as higher fracture toughness of ZZ edge direction. Our study provides significant insight into crack propagation mechanisms on atomic scales and highlights strategies for NNP developments of broader materials.

2D materials↗
DOE OSTI2024

Impact of cement composition, brine concentration, diffusion rate, reaction rate and boundary condition on self-sealing predictions for cement-CO 2 systems

Geological CO 2 storage (GCS) plays an important role in curbing CO 2 emissions by reducing the carbon footprint of difficult to decarbonize operations and achieve negative CO 2 emissions through activities like Bioenergy with Carbon Capture and Storage (BECCS) and Direct Air Carbon Capture and Storage (DACCS). Leakage of CO 2 through wells is an important concern when it comes to deployment of large-scale GCS. Existing wells in sites that are otherwise suitable for GCS can act as conduits for stored CO 2 to escape the reservoir. There is broad consensus that the main risk of leakage through wellbores is via fractures/damaged pathways. The results from several studies evaluating the permeability evolution of cement fractures in wells upon leakage of CO 2 agree that smaller fracture apertures, slower brine velocities and higher brine residence times promote self-sealing of fractures by mineral precipitation. Quantitatively, however, the differences in sealing conditions are significant and are typically attributed to differences in experimental conditions or model assumptions. Here we examine the sensitivity of our model, describing CO 2 leakage through wellbores, to cement composition, brine concentration, diffusion rates, and reaction rates. We also evaluate the impact of the boundary condition to allow comparisons between observations from experiments performed at constant flow rate and model predictions made at constant pressure conditions. Our results show that diffusion and reactions rates have the most impact on the self-sealing criteria for cement-CO 2 systems. In addition, conditions associated with self-sealing of fractures at constant flow rate require longer fractures, smaller fracture apertures, and slower velocities than under constant pressure.

58 GEOSCIENCES↗
DOE OSTI2022

Experimental results of conductive inserts to reduce nuclear fuel temperature during nuclear volumetric heating

Advanced fuel designs that incorporate thinner fuel UO2 pellets interspaced by high thermal conductivity inserts have been proposed, with the primary goals of reducing peak centerline temperatures and temperature gradients across fuel pellets and enhancing heat transfer from the fuel to the coolant. An initial series of experiments has been performed on this design, including laboratory experiments and a series of experiments using the Idaho National Laboratory (INL) Transient Reactor Test (TREAT) Facility, the latter of which compared thermal gradient driven fracture of standard pellet designs with that in the proposed advanced fuel design. Although reducing fracture is not the primary objective of the new fuel design, the lower thermal gradients are expected to reduce fracture, so it can serve as an indicator of the thermal behavior of this fuel in the reactor. The in-reactor tests were conducted at multiple linear heat generation rates and confirm the expected result that fracture in both the standard and advanced fuel pellets occurs during the first ramp to power in standard light-water reactor conditions. Post-irradiation examination of the experiment material was performed and included quantification of the extent of fracture in the fuel pellets. It was found that the advanced-design pellets reduce the extent of fracture in a statistically significant way. This confirms the expected behavior predicted by two-dimensional axisymmetric models of this experiment. Here in this study is an important first experimental confirmation of the efficacy of the proposed inserts for achieving their desired effect on the thermal behavior of the fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Modal Analysis of Ultrasonic Spot Welding for Lightweight Metals Joining

Ultrasonic spot welding (USW) represents one of the unique solid-state joining methods for lightweight materials such as magnesium alloy and aluminum alloy. However, the sonotrode vibration may have a detrimental impact on the sheet material and the existing welds, depending on the component geometry and vibration frequency. In this study, a modal analysis tool based on steady-state dynamics was developed for ultrasonic spot welding which features a cyclic load applied to the sheets during the joining process. Through predicting relative motion and shear stress at the faying surfaces, coupon geometry and weld spacing are identified as two major factors that affect the welding reliability and joint quality in USW. The model was validated via welding experiments on aluminum alloy and magnesium alloy and relevant characterization of temperature distribution, joint strength as well as fracture location.

36 MATERIALS SCIENCE↗