Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “RESIDUAL STRESSES”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Constitutive Model Development for Aging Polymer Encapsulants (ASC P&EM FY2021 L2 Milestone 7836)

This SAND report fulfills the completion requirements for the ASC Physics and Engineering Modeling Level 2 Milestone 7836 during Fiscal Year 2021. The Sandia Simplified potential energy clock (SPEC) non-linear viscoelastic constitutive model was developed to predict a whole host of polymer glass physical behaviors in order to provide a tool to assess the effects of stress on these materials over their lifecycle. Polymer glasses are used extensively in applications such as electronics packaging, where encapsulants and adhesives can be critical to device performance. In this work, the focus is on assessing the performance of the model in predicting material evolution associated with long-term physical aging, an area that the model has not been fully vetted in. These predictions are key to utilizing models to help demonstrate electronics packaging component reliability over decades long service lives, a task that is very costly and time consuming to execute experimentally. The initiating hypothesis for the work was that a model calibration process can be defined that enables confidence in physical aging predictions under ND relevant environments and timescales without sacrificing other predictive capabilities. To test the hypothesis, an extensive suite of calibration and aging data was assembled from a combination of prior work and collaborating projects (Aging and Lifetimes as well as the DoD Joint Munitions Program) for two mission relevant epoxy encapsulants, 828DGEBA/DEA and 828DGEBA/T403. Multiple model calibration processes were developed and evaluated against the entire set of data for each material. A qualitative assessment of each calibration's ability to predict the wide range of aging responses was key to ranking the calibrations against each other. During this evaluation, predictions that were identified as non-physical, i.e., demonstrated something that was qualitatively different than known material behavior, were heavily weighted against the calibration performance. Thus, unphysical predictions for one aspect of aging response could generate a lower overall rating for a calibration process even if that process generated better quantitative predictions for another aspect of aging response. This insurance that all predictions are qualitatively correct is important to the overall aim of utilizing the model to predict residual stress evolution, which will depend on the interplay amongst the different material aging responses. The DSC-focused calibration procedure generated the best all-around aging predictions for both materials, demonstrating material models that can qualitatively predict the whole host of different physical aging responses that have been measured. This step forward in predictive capability comes from an unanticipated source, utilization of calorimetry measurements to specify model parameters. The DSC-focused calibration technique performed better than compression-focused techniques that more heavily weigh measurements more closely related to the structural responses to be predicted. Indeed, the DSC-focused calibration procedure was only possible due to recent incorporation of the enthalpy and heat capacity features into SPEC that was newly verified during this L2 milestone. Fundamentally similar aspects of the two material model calibrations as well as parametric studies to assess sensitives of the aging predictions are discussed within the report. A perspective on the next steps to the overall goal of residual stress evolution predictions under stockpile conditions closes the report.

36 MATERIALS SCIENCE↗
NASA NTRS1999

High Temperature Mechanical Characterization and Analysis of Al2O3 /Al2O3 Composition

Sixteen ply unidirectional zirconia coated single crystal Al2O3 fiber reinforced polycrystalline Al2O3 was tested in uniaxial tension at temperatures to 1400 C in air. Fiber volume fractions ranged from 26 to 31%. The matrix has primarily open porosity of approximately 40%. Theories for predicting the Young's modulus, first matrix cracking stress, and ultimate strength were applied and evaluated for suitability in predicting the mechanical behavior of Al2O3/Al2O3 composites. The composite exhibited pseudo tough behavior (increased area under the stress/strain curve relative to monolithic alumina) from 22 to 1400 C. The rule-of-mixtures provides a good estimate of the Young's modulus of the composite using the constituent properties from room temperature to approximately 1200 C for short term static tensile tests in air. The ACK theory provides the best approximation of the first matrix cracking stress while accounting for residual stresses at room temperature. Difficulties in determining the fiber/matrix interfacial shear stress at high temperatures prevented the accurate prediction of the first matrix cracking stress above room temperature. The theory of Cao and Thouless, based on Weibull statistics, gave the best prediction for the composite ultimate tensile strength.

Gyekenyesi, John Z.↗
NASA NTRS2000

NDE for Material Characterization in Aeronautic and Space Applications

This paper describes selected nondestructive evaluation (NDE) approaches that were developed or tailored at the NASA Glenn Research Center for characterizing advanced material systems. The emphasis is on high-temperature aerospace propulsion applications. The material systems include monolithic ceramics, superalloys, and high temperature composites. In the aeronautic area, the highlights are cooled ceramic plate structures for turbine applications, F-TiAl blade materials for low-pressure turbines, thermoelastic stress analysis (TSA) for residual stress measurements in titanium based and nickel based engine materials, and acousto ultrasonics (AU) for creep damage assessment in nickel-based alloys. In the space area, examples consist of cooled carbon-carbon composites for gas generator combustors and flywheel rotors composed of carbon fiber reinforced polymer matrix composites for energy storage on the international space station (ISS). The role of NDE in solving manufacturing problems, the effect of defects on structural behavior, and the use of NDE-based finite element modeling are discussed. NDE technology needs for improved microelectronic and mechanical systems as well as health monitoring of micro-materials and components are briefly discussed.

Baaklini, George Y.↗
NASA NTRS2013

Stress Free Temperature Testing and Calculations on Out-of-Autoclave Composites

Future launch vehicles will require the incorporation of large composite parts that will make up primary and secondary components of the vehicle. NASA has explored the feasibility of manufacturing these large components using Out-of-Autoclave impregnated carbon fiber composite systems through many composites development projects. Most recently, the Composites for Exploration Project has been looking at the development of a 10 meter diameter fairing structure, similar in size to what will be required for a heavy launch vehicle. The development of new material systems requires the investigation of the material properties and the stress in the parts. Residual stress is an important factor to incorporate when modeling the stresses that a part is undergoing. Testing was performed to verify the stress free temperature with two-ply asymmetric panels. A comparison was done between three newly developed out of autoclave IM7/Bismaleimide (BMI) systems. This paper presents the testing results and the analysis performed to determine the stress free temperature of the materials

Cox, Sarah B.↗
NASA NTRS2014

Recent Developments and Challenges Implementing New and Improved Stress Intensity Factor (K) Solutions in NASGRO for Damage Tolerance Analyses

Fatigue crack growth analysis software has been available to damage tolerance analysts for many years in either commercial products or via proprietary in-house codes. The NASGRO software has been publicly available since the mid-80s (known as NASA/FLAGRO up to 1999) and since 2000 has been sustained and further developed by a collaborative effort between Southwest Research Institute® (SwRI®), the NASA Johnson Space Center (JSC), and the members of the NASGRO Industrial Consortium. Since the stress intensity factor (K) is the foundation of fracture mechanics and damage tolerance analysis of aircraft structures, a significant focus of development efforts in the past fifteen years has been geared towards enhancing legacy K solutions and developing new and efficient numerical K solutions that can handle the complicated stress gradients computed by today’s analysts using detailed finite element models of fatigue critical locations. This paper provides an overview of K solutions that have been recently implemented or improved for the analysis of geometries such as two unequal through cracks at a hole and two unequal corner cracks at a hole, as well as state-of-the-art weight function models capable of computing K in the presence of univariant and/or bivariant stress gradients and complicated residual stress distributions. Some historical background is provided to review how common K solutions have evolved over the years, including selective examples from the literature and from new research. Challenges and progress in rectifying discrepancies between older legacy solutions and newer models are reviewed as well as approaches and challenges for verification and validation of K solutions. Finally, a summary of current challenges and future research and development needs is presented. A key theme throughout the presentation of this paper will be how members of the aerospace industry have collaborated with software developers to develop a practical analysis tool that is used world-wide to support new design as well as the ongoing sustainment and airworthiness of commercial and military aircraft.

Cardinal, Joseph W.↗
NASA NTRS2026

Microstructural Evolution and Mechanical Properties of LP-DED NASA HR-1 – A Hydrogen Resistant AM Superalloy for Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has actively pursued metal additive manufacturing (AM) technologies for spaceflight applications since the late 2000s. AM offers transformative advantages in cost, schedule, part consolidation, and design flexibility. Among the various AM techniques, laser powder directed energy deposition (LP-DED) is particularly well suited for fabricating complex geometries with fine feature resolution. In propulsion systems that utilize high-pressure gaseous hydrogen—such as liquid hydrogen rocket engines—hydrogen environment embrittlement (HEE) presents a serious threat to material performance 1,2 . Mechanical property degradation under these conditions can compromise component reliability, especially under cyclic loading. To address this challenge, NASA developed NASA HR-1 (Hydrogen Resistant-1) as a solution for liquid rocket engine components operating in hydrogen-rich environments, using the LP-DED technique 3-9 . A key component in a liquid rocket engine is the exhaust nozzle, which is typically regeneratively cooled (regen) due to the high heat flux. NASA HR-1 was specifically developed for regen nozzle applications using hydrogen as a propellant, providing resistance to HEE, a critical issue for many materials. The AM version of NASA HR-1 was also formulated to achieve high ultimate tensile strength, along with high yield strength and ductility in this environment 5,6 . Low-cycle fatigue (LCF) is another important consideration in nozzle design, as components are expected to endure multiple starts and missions. Additionally, the LP-DED version of the alloy exhibits improved thermal conductivity compared to its wrought counterpart, which benefits nozzle cooling. Overall, NASA HR-1 offers an excellent balance of high strength, HEE resistance, LCF performance, thermal conductivity, and ductility to meet the demanding requirements of channel-cooled nozzles and other components used with hydrogen and other propellants. The LP-DED–processed NASA HR-1 requires several post-processing heat treatment steps to achieve the material properties desirable for its intended application 6 . These steps include stress relief, homogenization, solution annealing, and aging for precipitation hardening. The stress relief treatment mitigates residual stresses accumulated during the LP-DED process and minimizes the potential for distortion. Homogenization, a common step for AM materials, reduces elemental segregation and promotes recrystallization to develop a more equiaxed grain structure. The subsequent solution annealing treatment heats the part to a solid solution temperature to dissolve the undesirable η-phase that forms during cooling from homogenization, followed by rapid cooling to retain an η-phase–free microstructure. Finally, aging promotes precipitation of the strengthening γ′ phase in the alloy. The integration of compositional design and optimized thermal processing enables high-quality LP-DED NASA HR-1 components with excellent microstructural and mechanical stability. Improved chemical and microstructure homogeneity enhances ductility and fatigue resistance—both critical for safe and reliable operation in high-pressure hydrogen environments. NASA has successfully fabricated and hot-fire tested multiple subscale and full-scale channel wall nozzles using LP-DED NASA HR-1 5,6, 9-14 . These efforts included process refinements to support thin-wall construction and various channel geometries. Throughout development, several key observations emerged. After homogenization, the as-built columnar grain structure transforms into a fully equiaxed microstructure. However, subsequent treatments—such as solution annealing and aging—result in changes that are more difficult to track. The grain structure remains largely unchanged, and the γ′ precipitates, typically 5–10 nm in diameter, are beyond the resolution of scanning electron microscopy (SEM). While transmission electron microscopy (TEM) can resolve these fine precipitates, TEM sample preparation is time-consuming and difficult for LP-DED material. As an alternative, differential scanning calorimetry (DSC) offers a useful, qualitative approach to monitor precipitate evolution throughout different stages of heat treatment. The overall goal is to improve the understanding of how heat treatment affects the microstructure and mechanical performance of LP-DED NASA HR-1. This paper presents heat treatment design considerations, microstructural characterization, mechanical testing – including tensile and LCF testing in both air and hydrogen environments.

Superalloy↗
DOE OSTI2022

Stress corrosion cracking mechanism of cold spray coating on a galvanically similar substrate

Here, the chloride-induced stress corrosion cracking (CISCC) mechanism of cold spray (CS) coating on a galvanically similar substrate is investigated. Arc welded 304L stainless steel (SS) specimens are loaded into four-point bend fixtures, cold sprayed with 304L SS, then immersed in boiling MgCl 2 . Interconnected porosity forms through crevice corrosion along CS splat boundaries, allowing corrosive species to penetrate through the CS layer. Nevertheless, the substrate is resistant to CISCC likely because of compressive stress introduced by peening during CS particle impacts. These findings underscore the importance of residual stress in the environmental degradation of CS coatings or repairs of engineering structures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1966

Pyrolytic graphite.

Pyrolytic graphite production by thermal decomposition of hydrocarbon gas on heated surface, noting annealing, alloying and residual stresses

PYROLYTIC GRAPHITE↗
DOE OSTI2023

Modeling of Stress Distribution in Molten Salt Thermal Energy Storage Tanks for In-Service Central Receiver Power Plants

Failures in molten nitrate salts thermal energy storage tanks (TES) have been occurring in several concentrating solar power (CSP) plants around the world after a few months or years of operation. These failures are mainly related to a combination of high stress, corrosion, large deformation, and thermal cycling. Most of these failures are a consequence of the infancy of this technology; technical standards for design, fabrication, implementation, and operation of molten salt tanks operating at temperatures up to 565 degrees Celsius do not exist and most of current in-service tanks have been designed using the recommendations from the American Petroleum Institute (API) 650 and the American Society of Mechanical Engineers ASME section II standards, which are applicable for TES tanks operating at lower temperatures. We have developed a 3-dimensional model of a representative molten salt hot tank design that uses typical CSP plant operation conditions and allows determining the temperature and stress distribution in the tank. The model also considers the initial floor residual stresses and distortion after its welding fabrication. We have identified critical thermal gradients in the tank floor and shell and locations in the tank where the stresses are high and could become susceptible points for failure.

concentrating solar power↗
NASA NTRS1977

Lamination residual strains and stresses in hybrid laminates

An investigation is conducted of the effects of hybridization on the magnitude of lamination residual stresses. Eight-ply graphite/Kevlar 49/epoxy and graphite/S-glass/epoxy laminates were studied. The same matrix resin was selected for all basic materials to ensure compatibility and uniform curing of the various plies. The specimens, with inserted strain gages and thermocouples, were subjected to curing and postcuring cycles in an autoclave. Subsequently, the specimens were subjected to a thermal cycle from room temperature to 444 K and down to room temperature. It was found that hydridizing reduces apparently residual strains and stresses in the graphite plies. However, these strains were not affected much by the type and degree of hybridization.

Daniel, I. M.↗
DOE OSTI2017

Probing elastically or plastically induced structural heterogeneities in bulk metallic glasses by nanoindentation pop-in tests

Shear banding dynamics in bulk metallic glasses (BMGs) is manifested by the spatiotemporal evolution of strain fields which in turn depend on structural heterogeneities. The spacing of these heterogeneities, as a characteristic length scale, was determined from the analysis of nanoindentation pop-in tests using a stochastic model. Furthermore, the pre-stress by elastic bending and residual stress by plastic bending of BMG plates were found to dramatically decrease such spacings, thus increasing heterogeneity density and mechanically rejuvenating the glass structure.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Tensile and flexural strength of non-graphitic superhybrid composites: Predictions and comparisons

Equations are presented and described which can be used to predict bounds on the tensile and flexural strengths of nongraphitic superhybrid (NGSH) composites. These equations are derived by taking into account the measured stress-strain behavior, the lamination residual stresses and the sequence of events leading to fracture. The required input for using these equations includes constituents, properties (elastic and strength), NGSH elastic properties, cure temperature, and ply stress influence coefficients. Results predicted by these equations are in reasonably good agreement with measured data for strength and for the apparent knees in the nonlinear stress-strain curve. The lower bound values are conservative compared to measured data. These equations are relatively simple and are suitable for use in the preliminary design and initial sizing of structural components made from NGSH composites.

Chamis, C. C.↗
NASA NTRS1979

Tensile and flexural strength of nongraphitic superhybrid composites - Predictions and comparisons

Equations are presented and described which can be used to predict bounds on the tensile and flexural strengths of nongraphitic superhybrid (NGSH) composites. These equations are derived by taking into account the measured stress-strain behavior, the lamination residual stresses and the sequence of events leading to fracture. The required input for using these equations includes constituent composites, elastic and strength properties, NGSH elastic properties, cure temperature, and ply stress influence coefficients. Results predicted by these equations are in reasonably good agreement with measured data for strength and for the apparent 'knees' in the nonlinear stress-strain curve. The lower bound values are conservative compared to measured data. These equations are relatively simple and should be suitable for use in the preliminary design and initial sizing of structural components made from NGSH composites.

Chamis, C. C.↗
NASA NTRSDate not supplied

Nanomechanical Characterization of Additive Manufactured GRCop-42 Alloy Developed by Directed Energy Deposition Methods

Propulsion applications such as combustion chambers and nozzles for liquid rocket engines require the use of unique materials with superior mechanical and thermal properties. GRCop-42(Cu-4 wt.% Cr-2 wt.% Nb) is one such candidate material developed by NASA and is now being manufactured using additive manufacturing (AM) techniques. AM offers a unique processing environment different from traditional metal fabrication processes. This study characterized the mechanical and structural properties of as-deposited and heat-treated GRCop-42manufactured with Blown Powder Directed Energy Deposition (BPD)based on preliminary testing. The materials were characterized using several techniques including surface profiling by laser microscopy, mechanical stiffness by instrumented indentation, crystal structure, residual stress measurements using XRD and residual XRD, and chemical composition and microstructural evaluation using SEM with EBSD. The results of the study are compared using the BPD techniques for samples in the as-deposited and heat-treated conditions.

GRCop-42↗