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 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
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↗
DOE OSTI2017

Damage tolerance of nuclear graphite at elevated temperatures

Nuclear-grade graphite is a critically important high-temperature structural material for current and potentially next generation of fission reactors worldwide. It is imperative to understand its damage-tolerant behaviour and to discern the mechanisms of damage evolution under in-service conditions. Here we perform in situ mechanical testing with synchrotron X-ray computed micro-tomography at temperatures between ambient and 1,000 °C on a nuclear-grade Gilsocarbon graphite. We find that both the strength and fracture toughness of this graphite are improved at elevated temperature. Whereas this behaviour is consistent with observations of the closure of microcracks formed parallel to the covalent-sp 2 -bonded graphene layers at higher temperatures, which accommodate the more than tenfold larger thermal expansion perpendicular to these layers, we attribute the elevation in strength and toughness primarily to changes in the residual stress state at 800–1,000 °C, specifically to the reduction in significant levels of residual tensile stresses in the graphite that are ‘frozen-in’ following processing.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Onsager's symmetry relation and the residual parallel Reynolds stress in a magnetized plasma with electrostatic turbulence

The physics of the residual parallel Reynolds stress in a rotating plasma with electrostatic turbulence is explicitly identified by using the transport formulation of the gyrokinetic turbulence. It is clarified that the residual stress consists of four terms, among which are the cross terms due to the pressure gradient and the temperature gradient and the terms related to the turbulent acceleration impulse and the turbulent heating rate. The last two terms are identified for the first time, and are shown to cause analogous residual term in the heat flux. Meanwhile, the transport matrix reveals diffusion in the phase space. The transport matrix is demonstrated to satisfy the Onsager's symmetry relation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1975

Stress corrosion susceptibility of stress-coined fastener holes in aircraft structures

The cold working process of stress coining is used to provide fatigue improvement of fastener holes in aircraft structures. The cold working produces a radial flow of the metal. The residual stresses resulting from stress coining provide protection against fatigue damage by opposing the applied tensile stresses in service at the edge of the fastener hole. However, it is shown in this paper that in addition to the compressive stresses surrounding the stress coined hole, there are tensile stresses that result from the coining operation and that these residual tensile stresses can have a deleterious effect on the stress corrosion susceptibility of the postcoined structure.

Carter, A. E.↗
DOE OSTI2016

Inspection of Dry Storage Casks Using PGAA and NAA Techniques

In this effort, an assessment of a chloride detection method is performed for inspecting the surfaces of dry cask storage system (DCSS) canisters, with focus on the implementation of a non-destructive nuclear analysis and methodology. Some DCSS canisters (especially those located in coastal environments) will be exposed to marine environments, which can cause atmospheric stress corrosion cracking (SCC). Chloride deposits on canister surfaces provide the corrosive environment necessary for atmospheric SCC with the residual stresses and materials properties conditions. The most susceptible regions on the canister surface are the weld areas, or where cold work has been performed, and may provide the necessary driving force for crack growth. The heat-affected zones (HAZs) near welds are also potentially susceptible to atmospheric SCC due to sensitization of the material caused by chromium depletion during the welding process. Information collected from the field and from laboratory studies has not been able to rule out the possibility of atmospheric chloride induced stress corrosion cracking (CISCC), although no occurrences of atmospheric SCC in DCSS canisters have been detected to-date. A number of researchers have demonstrated that localized corrosion can take place under such situations on materials commonly used for interim storage containers, including 304SS (Cook et al. 2010; Shirai et al. 2011) and 316SS (Tani et al. 2009). In this summary, the preliminary results of a neutron activation analysis (NAA) and prompt gamma activation analysis (PGAA) are performed using MCNP6, a highly sophisticated, multi-particle Monte Carlo simulation code (with the employment of the high performance computing system at the Idaho National Laboratory), and confirm the feasibility of using PGAA and NAA as an environmental inspection methodology for detection and monitoring of small quantities of chlorine on canister surfaces. The specific signature of gamma rays due reactions of sea salt constituents are documented and summarized in this paper. The environmental constituent for passive oxide film breaching is chlorine, which can cause pitting initiation and incubation time that may lead to cracking in stainless steel. Therefore, an assessment of chloride presence at a canister surface is essential before moving to other nondestructive analysis (NDA) methods for detection of pitting and cracking. Two nonlinear acoustic techniques will also be used in our integrated research project (IRP) research study that proves to be useful in the detection of SCC: nonlinear resonant ultrasound spectroscopy (NRUS), and time revisited elastic nonlinear diagnostic (TREND). These two techniques are complementary to marine atmospheric detection techniques. In this presentation only PGAA and NAA are described in detail. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

Evolution of microstructural defects with strain effects in germanium nanocrystals synthesized at different annealing temperatures

Ge nanocrystals (Ge-ncs) were produced by implantation of {sup 74}Ge{sup +} into a SiO{sub 2} film on (100) Si, followed by high-temperature annealing from 700 °C to 1100 °C. Transmission electron microscopy (TEM) studies show that the average size of Ge-ncs increases with the annealing temperature. High-resolution TEM (HRTEM) investigations reveal the presence of planar and linear defects in the formed Ge-ncs, whose relative concentrations are determined at each annealing temperature. The relative concentration of planar defects is almost independent of the annealing temperature up to 1000 °C. However, from 1000 °C to 1100 °C, its concentration decreases dramatically. For the linear defects, their concentration varies considerably with the annealing temperatures. In addition, by measuring the interplanar spacing of Ge-ncs from the HRTEM images, a strong correlation is found between the dislocation percentage and the stress field intensity. Our results provide fundamental insights regarding both the presence of microstructural defects and the origin of the residual stress field within Ge-ncs, which can shed light on the fabrication of Ge-ncs with quantified crystallinity and appropriate size for the advanced Ge-nc devices. - Highlights: • Growth of Ge nanocrystals at different annealing temperatures was investigated. • Strain field has great effects on the formation of dislocations. • Different mechanisms are proposed to explain growth regimes of Ge nanocrystals.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Quantitative linkage between the stress at dislocation channel – Grain boundary interaction sites and irradiation assisted stress corrosion crack initiation

Localized deformation has emerged as a key factor in the crack initiation process for irradiated steels, as cracks are observed to nucleate preferentially at these sites. Using high resolution electron backscatter diffraction (HREBSD), the local stress tensor surrounding the dislocation channel-grain boundary interaction sites was quantified and coupled with fully determined grain boundary plane orientation information to determine, for the first time, the relationship between grain boundary normal stress and intergranular crack initiation in irradiated austenitic stainless steel. A Fe-13Cr-15Ni alloy was strained in simulated boiling water reactor, normal water chemistry after quantifying the residual stress tensor at discontinuous dislocation channel – grain boundary interaction sites where grain boundaries were determined to be well oriented with respect to the loading axis. Local stresses at the grain boundary were observed to reach magnitudes greater than 1.5 GPa at a distance of 200 nm from the intersection between the dislocation channel and the grain boundary. A pseudo-threshold stress of 0.9 GPa was measured, below which no cracking was observed. As the stress acting normal to the grain boundary increased above this value, the susceptibility to cracking increased with the cracking fraction reaching 100% at the high end of the stress range. This study shows for the first time that not only does intersection between discontinuous dislocation channels and grain boundaries result in peak local stresses, while the magnitude of the local tensile stress drives the crack initiation process.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Millimeter-Scale Exfoliation of hBN with Tunable Flake Thickness for Scalable Encapsulation

As a two-dimensional (2D) dielectric material, hexagonal boron nitride (hBN) is in high demand for applications in photonics, nonlinear optics, and nanoelectronics. Unfortunately, the high-throughput preparation of macroscopic-scale, high-quality hBN flakes with controlled thickness is an ongoing challenge, limiting device fabrication and technological integration. In this report we present a metal thin-film exfoliation method to prepare hBN flakes with millimeter-scale dimension, near-unity yields, and tunable flake thickness distribution from 1-7 layers, a substantial improvement over scotch tape exfoliation. The single crystallinity and high quality of the exfoliated hBN are demonstrated with optical microscopy, atomic force microscopy, Raman spectroscopy, and second harmonic generation. We further explore a possible mechanism for the effectiveness and selectivity based on thin-film residual stress measurements, density functional theory calculations, and transmission electron microscopy imaging of the deposited metal films. We find that the magnitude of the residual tensile stress induced by thin film deposition plays a key role in determining exfoliated flake thickness in a manner which closely resembles 3D semiconductor spalling. Lastly, we demonstrate that our exfoliated, large-area hBN flakes can be readily incorporated as encapsulating layers for other 2D monolayers. Altogether, this method brings us one step closer to the high throughput, mass production of hBN-based 2D photonic, optoelectronic, and quantum devices.

2D materials↗
DOE OSTI2025

Post-build stress-relief optimization for laser powder bed fusion 316H stainless steel

Nuclear energy remains a critical component of a diversified and efficient energy portfolio, offering reliable, high-capacity, and low-carbon power. However, in the U.S., aging infrastructure and the slow qualification and deployment of advanced materials and manufacturing techniques hinder progress in next-generation reactor technologies. This study explores the application of laser powder bed fusion (LPBF) additive manufacturing for stainless steel 316H, with a focus on optimizing post-build heat treatments to enhance material properties for high-temperature nuclear applications. The research targets the optimization of stress-relief temperatures to alleviate postbuild residual stresses, ensuring improvements in the microstructural corelated properties. A series of microstructural and mechanical evaluations were performed on LPBF-printed SS-316H samples which were subjected to annealing at temperatures varying between 650 °C and 850 °C. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that increasing the heattreatment temperature accelerated dislocation recovery. Vickers microhardness measurements showed an initial reduction in values, followed by stabilization over extended durations at all the temperatures. While higher temperatures facilitated faster recovery, they also promoted carbide precipitation along grain and solidification cell boundaries, narrowing the safe processing window. In contrast, heat treatment at 650°C preserved the cellular substructure and enabled controlled carbide precipitation over time. In conclusion, these findings highlight the importance of time–temperature optimization and suggest that 650°C for up to 2 h provides the most favorable balance between recovery and carbide control for a stress-relief treatment.

316 stainless steel↗
NASA NTRS1980

Influence of stress interaction on the behavior of off-axis unidirectional composites

The yield function for plane stress of a transversely isotropic composite lamina consisting of stiff, linearly elastic fibers and a von Mises matrix material is formulated in terms of Hill's elastic stress concentration factors and a single plastic constraint parameter. The above are subsequently evaluated on the basis of observed average lamina and constituent response for the Avco 5505 boron epoxy system. It is shown that inclusion of residual stresses in the yield function together with the incorporation of Dubey and Hillier's concept of generalized yield stress for anisotropic media in the constitutive equation correctly predicts the trends observed in experiments. The incorporation of the strong axial stress interaction necessary to predict the correct trends in the shear response is directly traced to the high residual axial stresses in the matrix induced during fabrication of the composite.

Pindera, M. J.↗
DOE OSTI2016

Diffraction and single-crystal elastic constants of Inconel 625 at room and elevated temperatures determined by neutron diffraction

In this work, diffraction and single-crystal elastic constants of Inconel 625 have been determined by means of in situ loading at room and elevated temperatures using time-of-flight neutron diffraction. Theoretical models proposed by Voigt, Reuss, and Kroner were used to determine single-crystal elastic constants from measured diffraction elastic constants, with the Kroner model having the best ability to capture experimental data. The magnitude of single-crystal elastic moduli, computed from single-crystal elastic constants, decreases and the single crystal anisotropy increases as temperature increases, indicating the importance of texture in affecting macroscopic stress at elevated temperatures. Finally, the experimental data reported here are of great importance in understanding additive manufacturing of metallic components as: diffraction elastic constants are required for computing residual stresses from residual lattice strains measured using neutron diffraction, which can be used to validate thermomechanical models of additive manufacturing, while single-crystal elastic constants can be used in crystal plasticity modeling, for example, to understand mechanical deformation behavior of additively manufactured components.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of Thickness on the Structure, Composition and Properties of Titanium Nitride Nano-Coatings

Titanium nitride (TiNx) coatings were grown by magnetron sputtering onto Si(1 0 0) substrates by varying time of deposition to produce coatings with variable thickness (dTiN) in the range of 20-120 nm. TiNx coatings were characterized by studying their structure, composition, and mechanical properties. Nuclear reaction analysis (NRA) combined with Rutherford backscattering spectrometry (RBS) analyses indicate that the grown coatings were stoichiometric TiN. Grazing incidence X-ray diffraction (GIXRD) measurements indicate that the texturing of TiN coatings changes as a function of dTiN. The (1 1 1) and (0 0 2) peaks appear initially; (1 1 1) becomes intense while (0 0 2) disappears with increasing dTiN. Dense, columnar grain structure was evident for all the coatings in electron microscopy analyses. The residual stress for TiN coatings with dTiN~120 nm was 1.07 GPa in compression while thinner samples exhibit higher values of stress.

Coatings↗
NASA NTRS1993

Elastic-plastic finite element analyses of an unidirectional, 9 vol percent tungsten fiber reinforced copper matrix composite

Micromechanical modeling via elastic-plastic finite element analyses were performed to investigate the effects that the residual stresses and the degree of matrix work hardening (i.e., cold-worked, annealed) have upon the behavior of a 9 vol percent, unidirectional W/Cu composite, undergoing tensile loading. The inclusion of the residual stress-containing state as well as the simulated matrix material conditions proved to be significant since the Cu matrix material exhibited plastic deformation, which affected the subsequent tensile response of the composite system. The stresses generated during cooldown to room temperature from the manufacturing temperature were more of a factor on the annealed-matrix composite, since they induced the softened matrix to plastically flow. This event limited the total load-carrying capacity of this matrix-dominated, ductile-ductile type material system. Plastic deformation of the hardened-matrix composite during the thermal cooldown stage was not considerable, therefore, the composite was able to sustain a higher stress before showing any appreciable matrix plasticity. The predicted room temperature, stress-strain response, and deformation stages under both material conditions represented upper and lower bounds characteristic of the composite's tensile behavior. The initial deformation stage for the hardened material condition showed negligible matrix plastic deformation while for the annealed state, its initial deformation stage showed extensive matrix plasticity. Both material conditions exhibited a final deformation stage where the fiber and matrix were straining plastically. The predicted stress-strain results were compared to the experimental, room temperature, tensile stress-strain curve generated from this particular composite system. The analyses indicated that the actual thermal-mechanical state of the composite's Cu matrix, represented by the experimental data, followed the annealed material condition.

Sanfeliz, Jose G.↗
DOE OSTI2013

EFFECTS OF LASER SHOCK PEENING ON SCC BEHAVIOR OF ALLOY 600

In this study, the effects of laser shock peening (LSP) on stress corrosion cracking (SCC) behavior of Alloy 600 in tetrathionate solution were investigated. The degree of sensitization was quantified using double loop electrochemical potentiokinetic reactivation (DLEPR) tests. The sensitized Alloy 600 was demonstrated to be susceptible to intergranular SCC in tetrathionate solution. Following LSP, residual stresses and the amount of plastic strain introduced in Alloy 600 were characterized. The effects of LSP on SCC susceptibility of Alloy 600 in tetrathionate solution were evaluated by slow strain rate tests and constant load tests. Results indicate a significant increase in resistance to crack initiation and decreased susceptibility to SCC after LSP.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Stress induced growth of Sn nanowires in a single step by sputtering method

Sn nanowires in aluminum film have been synthesized in a single step by co-sputtering of Al and Sn targets. Due to immiscibility of Sn and Al, co-sputtering leads to generation of stress in the composite film. In order to attain thermodynamic equilibrium, Sn separates from Al and diffuses towards the grain boundaries. External perturbation due to ambient atmosphere leads to corrosion at the grain boundaries forming pits which provide path for Sn to evolve. Owing to this, extrusion of Sn nanowires from Al film occurs to release the residual stress in the film.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Towards ultra-stiff materials: Surface effects on nanoporous materials

The significant rise in the strength and stiffness of porous materials at nanoscale cannot be described by conventional scaling laws. This letter investigates the effective Young's modulus of such materials by taking into account surface effect in a microcellular architecture designed for an ultralight material whose stiffness is an order of magnitude higher than most porous materials. We find that by considering the surface effects the predicted stiffness using Euler-Bernoulli beam theory compares well to experimental data for spongelike nanoporous gold with random microstructures. Analytical results show that, of the two factors influencing the effective Young's modulus, the residual stress is more important than the surface stiffness.

77 NANOSCIENCE AND NANOTECHNOLOGY↗