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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 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Surface smoothing for laser powder-bed Ti-6Al-4V by a transient liquid phase

Surface roughness is the primary driver of fatigue for additively manufactured metals. To address surface roughness, this work introduces a new method to smooth features beyond line-of-sight without material removal. The method applies a coating that triggers local surface remelting by activating a eutectic reaction during heat treatment. The associated liquid phase then wets and isothermally solidifies into a smoother surface. For Ti-6Al-4V fabricated with laser powder bed fusion, samples with and without TLP smoothing (using a Cu coating) were characterized with a suite of techniques, including mechanical testing, electron backscatter diffraction, synchrotron X-ray tomography, and fractography. TLP smoothing reduced surface roughness by 80% and amplified compressive residual stress at the surface by about 50%. With statistically equivalent virtual microstructures, crystal plasticity scrutinized the roles of phases, porosity, and surface roughness. Although the tensile strain-to-failure was reduced to 1% strain, the TLP smoothing process increased high-cycle fatigue strength by about 20% compared to control samples, pointing to future opportunities to optimize the new process through various coating compositions and heat treatment schedules. Overall, this work establishes a new paradigm for treating surfaces of materials for smoothness and compressive residual stress.

Additive manufacturing↗
DOE OSTI2025

Mechanistic Insights Into Fatigue Life Enhancement of High‐Strength Steel via Ultrasonic Impact Treatment

In this work we explore the impact of Ultrasonic Impact Treatment (UIT) on the fatigue performance of high‐strength microalloyed steel commonly used in crankshaft applications. Building on prior observations of fatigue life improvement with UIT, this work focuses on unraveling the process–structure–performance relationships underpinning these enhancements. Microstructural analysis revealed significant grain refinement in the near‐surface layers, with deformation depth increasing at higher impact energies. This led to increased surface hardness and the development of deeper compressive residual stresses, particularly in samples treated with higher impact energy. Rotating bending fatigue testing showed a substantial improvement in fatigue life for UIT‐treated samples, with the endurance limit nearly doubling compared with untreated specimens. Fractographic analysis revealed a transition in crack initiation from surface defects in untreated samples to interior regions in UIT‐treated samples, characterized by the formation of noninclusion‐induced granular bright facets (GBFs). The observed fatigue enhancement is attributed to the synergistic effects of strain hardening and compressive residual stresses, which increase the surface crack threshold and promote interior crack initiation. This study provides new mechanistic insight into UIT‐induced fatigue resistance and interior failure behavior in high‐strength steels.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Prestrain on the Fatigue Life of Superelastic Nitinol

Three types of fatigue testing are performed to elucidate the effects of prestraining superelastic Nitinol on its subsequent fatigue lifetime: rotary bending and tension–tension testing of wire, and beam bending using diamond-shaped specimens fabricated from tubing. Results show that local plastic deformation during prestraining induces residual stresses that have a pronounced effect on fatigue performance, enhancing performance when the fatigue duty cycle is of the same sense as the prestraining (tensile prestraining followed by a tensile duty cycle, for example), and decreasing fatigue lifetime when the sense of the duty cycle is opposite to that of prestraining. This provides an avenue to increasing fatigue lifetime, but more importantly it highlights the need to fully understand the nature of the duty cycle: for example, prestraining a stent by crimping it into a delivery catheter induces favorable residual stresses with respect to subsequent pulsatile fatigue, but might accelerate fracture in other modes, such as axial or crush fatigue. Caution is also advised when trying to apply data from “constant life diagrams” derived from the literature (Ref 1, 2 for example) that may not properly reflect the strain history of the device being analyzed.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Stress reduction of Cu-doped diamond-like carbon films from ab initio calculations

Structure and properties of Cu-doped diamond-like carbon films (DLC) were investigated using ab initio calculations. The effect of Cu concentrations (1.56∼7.81 at.%) on atomic bond structure was mainly analyzed to clarify the residual stress reduction mechanism. Results showed that with introducing Cu into DLC films, the residual compressive stress decreased firstly and then increased for each case with the obvious deterioration of mechanical properties, which was in agreement with the experimental results. Structural analysis revealed that the weak Cu-C bond and the relaxation of both the distorted bond angles and bond lengths accounted for the significant reduction of residual compressive stress, while at the higher Cu concentration the increase of residual stress attributed to the existence of distorted Cu-C structures and the increased fraction of distorted C-C bond lengths.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Surface integrity and fatigue behaviour of electric discharged machined and milled austenitic stainless steel

Machining of austenitic stainless steels can result in different surface integrities and different machining process parameters will have a great impact on the component fatigue life. Understanding how machining processes affect the cyclic behaviour and microstructure are of outmost importance in order to improve existing and new life estimation models. Milling and electrical discharge machining (EDM) have been used to manufacture rectangular four-point bend fatigue test samples; subjected to high cycle fatigue. Before fatigue testing, surface integrity characterisation of the two surface conditions was conducted using scanning electron microscopy, surface roughness, residual stress profiles, and hardness profiles. Differences in cyclic behaviour were observed between the two surface conditions by the fatigue testing. The milled samples exhibited a fatigue limit. EDM samples did not show the same behaviour due to ratcheting. Recrystallized nano sized grains were identified at the severely plastically deformed surface of the milled samples. Large amounts of bent mechanical twins were observed ~ 5 μm below the surface. Grain shearing and subsequent grain rotation from milling bent the mechanical twins. EDM samples showed much less plastic deformation at the surface. Surface tensile residual stresses of ~ 500 MPa and ~ 200 MPa for the milled and EDM samples respectively were measured. - Highlights: •Milled samples exhibit fatigue behaviour, but not EDM samples. •Four-point bending is not suitable for materials exhibiting pronounced ratcheting. •LAGB density can be used to quantitatively measure plastic deformation. •Grain shearing and rotation result in bent mechanical twins. •Nano sized grains evolve due to the heat of the operation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A constitutive model for glass–ceramic materials

Glass–ceramics have received recent attention for use in glass–ceramic to metal hermetic seals. Due to their heterogeneous microstructure, these materials exhibit a number of advantageous responses over conventional glass based seals. Key amongst them is the possibility of a controllable thermal strain response and apparent coefficient of thermal expansion which may be used to minimize thermally induced residual stresses for aforementioned seals. Furthermore, these behaviors result from an inorganic glass matrix and variety of crystalline ceramic phases including silica polymorph(s) that may undergo reversible solid-to-solid transformations with associated inelastic strain. Correspondingly, these materials exhibit complex thermomechanical responses associated with multiple inelastic mechanisms (viscoelasticity and phase transformation). While modeling these behaviors is essential for developing and analyzing the corresponding applications, no such model exists. Therefore, in this work a three-dimensional continuum constitutive model for glass–ceramic materials combining these various inelastic mechanisms is developed via an internal state variable approach. A corresponding fully implicit three dimensional numerical formulation is also proposed and implemented. The model is used to simulate existing experiments and validate the proposed formalism. As an example, the simple seal problem of a glass–ceramic seal inside a concentric metal shell is explored. Finally, the impact of the cooling rates, viscoelastic shift factors, and inelastic strain on final residual stress state are all investigated and the differing contributions highlighted.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Comparative study of the mechanical properties of nanostructured thin films on stretchable substrates

Comparative studies of the mechanical behavior between copper, tungsten, and W/Cu nanocomposite based on copper dispersoïd thin films were performed under in-situ controlled tensile equi-biaxial loadings using both synchrotron X-ray diffraction and digital image correlation techniques. The films first deform elastically with the lattice strain equal to the true strain given by digital image correlation measurements. The Cu single thin film intrinsic elastic limit of 0.27% is determined below the apparent elastic limit of W and W/Cu nanocomposite thin films, 0.30% and 0.49%, respectively. This difference is found to be driven by the existence of as-deposited residual stresses. Above the elastic limit on the lattice strain-true strain curves, we discriminate two different behaviors presumably footprints of plasticity and fracture. The Cu thin film shows a large transition domain (0.60% true strain range) to a plateau with a smooth evolution of the curve which is associated to peak broadening. In contrast, W and W/Cu nanocomposite thin films show a less smooth and reduced transition domain (0.30% true strain range) to a plateau with no peak broadening. These observations indicate that copper thin film shows some ductility while tungsten/copper nanocomposites thin films are brittle. Fracture resistance of W/Cu nanocomposite thin film is improved thanks to the high compressive residual stress and the elimination of the metastable β-W phase.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Fatigue behavior of thermal sprayed WC-CoCr- steel systems: Role of process and deposition parameters

Thermal spray deposited WC-CoCr coatings are extensively used for surface protection of wear prone components in a variety of applications. Although the primary purpose of the coating is wear and corrosion protection, many of the coated components are structural systems (aero landing gear, hydraulic cylinders, drive shafts etc.) and as such experience cyclic loading during service and are potentially prone to fatigue failure. It is of interest to ensure that the coating and the application process does not deleteriously affect the fatigue strength of the parent structural metal. It has long been appreciated that the relative fatigue life of a thermal sprayed component can be affected by the residual stresses arising from coating deposition. The magnitude of these stresses can be managed by torch processing parameters and can also be influenced by deposition effects, particularly the deposition temperature. In this study, the effect of both torch operating parameters (particle states) and deposition conditions (notably substrate temperature) were investigated through rotating bending fatigue studies. The results indicate a strong influence of process parameters on relative fatigue life, including credit or debit to the substrate's fatigue life measured via rotating bend beam studies. Damage progression within the substrate was further explored by stripping the coating off part way through fatigue testing, revealing a delay in the onset of substrate damage with more fatigue resistant coatings but no benefit with coatings with inadequate properties. Finally, the results indicate that compressive residual stress and adequate load bearing capability of the coating (both controlled by torch and deposition parameters) delay onset of substrate damage, enabling fatigue credit of the coated component.

36 MATERIALS SCIENCE↗
NASA NTRS1971

Effects of loading sequence for notched specimens under high-low two-step fatigue loading

The effects of loading sequence on crack-initiation period were investigated for notched aluminum-alloy specimens under high-low two-step loading with special emphasis on local cyclic stresses and strains at the notch root. Local stress and strain were determined by a procedure based on an equation proposed by Neuber which relates elastoplastic stress and strain at a notch. Local stress and strain were also measured experimentally to verify the Neuber equation. The effects of initial high load on the crack-initiation periods were demonstrated with notched specimens and were simulated in unnotched specimens fatigue tested with local stress sequences. An analysis of the results indicated that sequence effects were not caused solely by local residual stresses, as is usually assumed; the existence of a damaging effect, resulting from the high local strain cycles, was demonstrated. The sequence effects observed with notched specimens were interpreted as the combined result of residual stresses and high local strain cycles.

Crews, J. H., Jr.↗
DOE OSTI2023

Temporally continuous thermofluidic–thermomechanical modeling framework for metal additive manufacturing

Additive manufacturing (AM) is known to generate large magnitudes of residual stresses (RS) within builds due to steep and localized thermal gradients. In the current state of commercial AM technology, manufacturers generally perform heat treatments in effort to reduce the generated RS and its detrimental effects on part distortion and in-service failure. Computational models that effectively simulate the deposition process can provide valuable insights to improve RS distributions. Accordingly, it is common to employ Computational fluid dynamics (CFD) models or finite element (FE) models. While CFD can predict geometric and thermal-fluid behavior, it cannot predict the structural response (e.g., stress–strain) behavior. On the other hand, an FE model can predict mechanical behavior, but it lacks the ability to predict geometric and fluid behavior. Thus, an effectively integrated thermofluidic–thermomechanical modeling framework that exploits the benefits of both techniques while avoiding their respective limitations can offer valuable predictive capability for AM processes. In contrast to previously published efforts, the work herein describes a one-way coupled CFD-FEA framework that abandons major simplifying assumptions, such as geometric steady-state conditions, the absence of material plasticity, and the lack of detailed RS evolution/accumulation during deposition, as well as insufficient validation of results. Here, the presented framework is demonstrated for a directed energy deposition (DED) process, and experiments are performed to validate the predicted geometry and RS profile. Both single- and double-layer stainless steel 316L builds are considered. Geometric data is acquired via 3D optical surface scans and X-ray micro-computed tomography, and residual stress is measured using neutron diffraction (ND). Comparisons between the simulations and measurements reveal that the described CFD-FEA framework is effective in capturing the coupled thermomechanical and thermofluidic behaviors of the DED process. The methodology presented is extensible to other metal AM processes, including power bed fusion and wire-feed-based AM.

42 ENGINEERING↗
DOE OSTI2022

An Adaptive Geometry-Free Thermo-Mechanical Model for Directed Energy Deposition Process Modeling

This presentation describes a novel, geometry-free thermo-mechanical model with adaptive subdomain con- struction to accurately predict the thermal conditions, distortions, and residual stresses throughout the directed energy deposition (DED) process. A novel finite element workflow is designed to con- duct the numerical analysis, based on the multi-app and data transfer capabilities in the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE). Unlike with traditional methods, the part geometry in this model is not predefined. Instead, it is a combined effect of the processing parameters and material properties. At each time step, the model utilizes a subdomain construction paradigm to model the material deposition. A specialized mesh adaptivity scheme is incorporated to provide an accurate prediction while reducing the overall computational cost. The results generated by the proposed model show general agreement with the experimental measurements for the single track scan with varying processing parameters and demonstrate reasonable predictions for higher material buildups.

36 MATERIALS SCIENCE↗
DOE OSTI2021

On the existence of orthorhombic martensite in a near-α titanium base alloy used for additive manufacturing

Additive manufacturing is a state-of-the-art production technology to produce tailor-made and highly complex parts. Among various other alloys, Ti base alloys are frequently used in this manufacturing technique due to their well-balanced properties and their wide range of applications. Allotropic phases and the occurrence of athermal phase transformations are the main reasons why these alloys hold a great development potential and are the basis of extensive use. High cooling rates during manufacturing lead to martensitic phases and the formation of nanometer-sized microstructures resulting in extraordinary strength. Simultaneously, such high cooling rates cause a high amount of lattice defects and the occurrence of residual stresses, which finally may result in delamination effects and cracks. Usually, a common approach to reduce residual stresses during additive manufacturing is to decrease thermal gradients by increasing the heat input or preheating the building platform. Instead of applying the typical approaches to lower thermal gradients, this study deals with the origin of the ‘softer’ orthorhombic martensite by accelerating the solidification process. The implementation of the orthorhombic phase in bulk components was inspired by a new phase transformation herein reported for the first time in the powder material, which also validates the possible occurrence of two martensitic phases in the same alloy. Various sophisticated characterization techniques like high energy and high-temperature X-ray diffraction, high-resolution transmission electron microscopy as well as atom probe tomography were applied to characterize this softer orthorhombic martensitic phase in detail aiming to highlight the opportunities accompanied by this new approach for additive manufacturing of titanium alloys.

36 MATERIALS SCIENCE↗
NASA NTRS2009

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Thesken, John C.↗
NASA NTRS2006

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Greene, N.↗
DOE OSTI2019

Dry Sliding Wear Resistance of Cobalt Boride Coatings Formed on ASTM F1537 Alloy

New results about the wear resistance of CoB-Co{sub 2}B coatings under dry sliding conditions were estimated in this work. The cobalt boride coatings were developed at the surface of the ASTM F1537 alloy by means of the powder-pack boriding process using two experimental conditions: 1223 K with 6 h of exposure and 1273 K with 10 h of exposure. Before the sliding wear tests, Vickers depth-sensing microindentation tests were conducted on the cross section of the cobalt boride coatings to estimate the distribution of hardness, Young’s modulus, and residual stresses. Otherwise, the sliding wear tests were performed on both boriding conditions and on the untreated material, using a ball-on-flat configuration comprised of an alumina ball as a counterpart with applied loads between 5 and 20 N. The wear rates of the borided ASTM F1537 alloy were ranged between 4.02 and 8.91 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1} compared with the values of the untreated material (13.90 and 15.78 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1}) for the overall set of experimental conditions; nevertheless, the influence of boriding conditions (1273 K with 10 h of exposure) tended to increase the CoB coating thickness, developing a more brittle layer that decreased the sliding wear resistance at the surface of the borided ASTM F1537 alloy. Finally, the presence of failure mechanisms on the surface of the wear tracks was analyzed for both borided ASTM F1537 alloy and untreated material.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Stress and efficiency studies in EFG

The goals of this program were: (1) to define minimum stress configurations for silicon sheet growth at high speeds; (2) to quantify dislocation electrical activity and their limits on minority carrier diffusion length in deformed silicon; and (3) to study reasons for degradation of lifetime with increases in doping level in edge-defined film-fed growth (EFG) materials. A finite element model was developed for calculating residual stress with plastic deformation. A finite element model was verified for EFG control variable relationships to temperature field of the sheet to permit prediction of profiles and stresses encountered in EFG systems. A residual stress measurement technique was developed for finite size EFG material blanks using shadow Moire interferometry. Transient creep response of silicon was investigated in the temperature range between 800 and 1400 C in strain and strain regimes of interest in stress analysis of sheet growth. Quantitative relationships were established between minority carrier diffusion length and dislocation densities using Electron Beam Induced Current (EBIC) measurement in FZ silicon deformed in four point bending tests.

Source record↗
DOE OSTI2021

Implementation of Disruptive Designs for Gas Turbine Components Utilizing Additive Manufacturing

Electron beam melting (EBM) is an additive manufacturing process used to print metallic components with complex geometries for aerospace applications. A preheating characteristic enables this technology to avoid large accumulation of residual stress during printing. However, cracking mechanisms particularly in Ni-based superalloys are associated with not only residual stress but also with microstructure (i.e., solidification morphology, transient evolution of γ'). Siemens is committed to AM technology for gas turbine applications. The ability to novel predictive designs of turbine blades would reduce process development time and allow acquisition of key microstructure and performance data early in a design campaign. Siemens initiated a project to establish the design rules for the fabrication of non-printable Nibased superalloys. This phase 1 program demonstrates the feasibility for virtual fabrication of the actual blade geometries through EBM process.

42 ENGINEERING↗
NASA NTRS1982

The metallurgical structure and mechanical properties at low temperature of Nitronic 40 with particular reference to its use in the construction of models for cryogenic wind tunnels

Nitronic 40 was chosen for the construction of Pathfinder I, an R & D model for use in the National Transonic Facility, because of its good mechanical properties at cryogenic temperatures. Nitronic 40 contains delta ferrite and is in a sensitized condition. Heat treatments carried out to remove residual stresses also caused further sensitization. Experiments showed that heat treatment followed by cryoquenching removed the sensitization without creating residual stresses. Heat treatment at temperatures of 2200 F was used to remove the delta ferrite but with little success and at the cost of massive grain growth. The implications of using degraded Nitronic 40 for cryogenic wind tunnel models are discussed, together with possible acceptance criteria.

Wigley, D. A.↗