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DOE OSTI2024

A Multiphysics Multiscale Simulation Platform for Damage, Environmental Degradation, and Life Prediction of CMCs in Extreme Environments

This project successfully developed a multiphysics, multiscale computational framework to enhance the design and development of CMCs, with a focus on modeling highly nonlinear, time-dependent damage mechanisms and material degradation under extreme conditions, such as those experienced in turbine service environments. The project made significant advances in improving our understanding of progressive damage, oxidative degradation, and time-dependent inelastic deformation in CMCs, with particular attention to the role of uncertainties in predictions. Key outcomes include the integration of advanced material characterization, uncertainty quantification, and multiphysics constitutive models to predict the behavior of CMCs over their service life. A novel multiscale methodology was employed, which integrated microscale constituent behaviors with structural-scale responses, enabling the manufacturing defects in the microstructure that are prone to damage nucleation. Through the development of DL algorithms, the project advanced the prediction of damage initiation and crack propagation, taking into account the defect morphology and statistical variations across multiple scales. The framework was rigorously validated using thermomechanical experiments, which tested CMCs under various mechanical loadings at elevated temperatures, further enhancing the model's predictive capability. Overall, the research outcomes have provided a more accurate, reliable method for predicting CMC component life, significantly advancing material design, and improving component reliability in extreme environments. This work has strong implications for the optimization of turbine components and other high-performance applications where CMCs are used.

03 NATURAL GAS↗

DOE OSTI2025

Radiation damage effects in beryllium for next generation neutrino beam targetry (Final Technical Report)

Current and future high-power accelerators put severe requirements on materials used for target and beam windows and target facilities have been recognized as a critical challenge in development of future particle accelerators. In accelerators, window and target materials are exposed to extreme conditions, which include bombardment with very high energy protons (1- 100 GeV) and thermomechanical shock waves. Radiation can cause direct damage in the material, and it leads to production of transmutation products (especially helium), both phenomena having a potential adverse effect on the stability and durability of the target/window material. At high enough temperatures, He can aggregate to form gas bubbles, which in turn cause significant dimensional changes (swelling), enable easy crack propagation, and eventually cause failure by fracture. On the other hand, if the temperature is too low, radiation damage accumulates in the form of internal defects (e.g., dislocations), leading to hardening and a decreased ductility of the material. In this project, we will focus on beryllium since it is considered to be one of the candidate materials for beam windows and targets in the next-generation proton accelerators, e.g., the Long Baseline Neutrino Facility (LBNF). Radiation effects in Be have been studied in the context of nuclear fusion reactor applications. However, key differences exist between reactor and accelerator conditions, including neutron vs. proton irradiation, continuous vs. pulsed beam flux, much higher energies of bombarding particles in accelerators, and higher operating temperatures for typical reactors. For example, the impact of beam pulsing on the radiation damage and the He bubble kinetics is largely unknown. While results obtained on Be from fusion research might not be directly transferrable to understanding target materials, there is an opportunity to bring state-of-the-art tools from materials research in nuclear reactors to aid design of target and beam window materials in high-power accelerators. To this end, the overarching goal of this project are to develop an experimentally-validated computational framework capable of predicting radiation damage evolution in beryllium relevant to beam window and target conditions, focusing on He bubble formation and growth as a function of irradiation temperature. Our model will be based on the cluster dynamics formalism, where size distribution of defects and He bubbles is simulated as a function of time, temperature, and radiation dose. Parameters for the model will be taken from published experiments and from high-fidelity atomistic simulations proposed in this project. In addition, we will carry out a series of targeted ex-situ and in-situ dual-beam experiments using low-energy protons to provide critical data for validation of the model on the effects of radiation on He clustering, He bubble distribution, and dislocation loop density/size in proton irradiated Be.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Multiscale Thermomechanical Damage Model with Internal State Variables for Ceramic Matrix Composites

A length scale-dependent matrix damage model has been developed to simulate the response of ceramic matrix composites (CMCs). This model captures damage initiation and propagation in the brittle matrix material by employing internal state variable (ISV) theory within a multiscale modeling framework to obtain damaged matrix stress-strain constitutive relationships at each length scale. Material degradation due to matrix cracking is captured by a damage variable determined using fracture mechanics and the self-consistent scheme. An additional state variable is introduced to capture the nucleation and growth of matrix porosity, a key mechanism contributing to matrix nonlinearity. Porosity occurs as a result of material diffusion around grain boundaries and the growth of the porosity state variable is related to the material entropy dissipation and the volumetric strain. The nonlinear predictive capabilities of the material model are demonstrated for monolithic silicon carbide, unidirectional (UD) carbon fiber/silicon carbide matrix (C/SiC) CMC, and five-harness satin (5HS) woven C/SiC CMC.

Skinner, Travis D.↗

DOE OSTI2026

Influence of Oxygen Flow and Stoichiometry on Optical Properties and Damage Resistance of Hafnium Oxide Thin Films

Hafnium oxide (HfO 2 ) is predominantly used as a high-index material in multi-layer dielectric coatings for high-peak- and high-average-power lasers, but laser damage often initiates within the HfO 2 layers despite their wide bandgap. Oxygen deficiency during deposition can introduce vacancy-related sub-bandgap states and absorptive defects, lowering damage resistance. This study investigates how oxygen flow during HfO 2 deposition with ion beam sputtering (IBS) affects its stoichiometry, defect formation, and nanosecond laser-induced damage threshold (LIDT) and whether single-layer trends predict multilayer performance. Single layers were deposited at varying oxygen flows, characterized for optical and structural properties, and tested for the LIDT at 1064 nm and 355 nm. Increasing oxygen flow drove the layer toward near-stoichiometric HfO 2 , reduced the refractive index, and altered the density of surface pinhole-like features. The single-layer LIDT at 355 nm increased with oxygen, whereas the 1064 nm LIDT was comparatively less sensitive to oxygen flow, consistent with the wavelength-dependent roles of absorptive precursors and microstructural defects. In contrast, a HfO 2 -based high-reflector (HR) showed a higher LIDT at lower oxygen flow, indicating that the family of damage precursors changes between single layers and multilayers; in stacks, structural properties such as stress, gas entrapment and thermal dissipation may outweigh the isolated absorptive defects found in single layers. These results demonstrate that the optimal oxygen flow condition depends on both LIDT wavelength and film architecture. We identified, for single layers, a 15–35 sccm window for maximizing the 1064 nm LIDT and a high-flow optimum (45 sccm) for the 355 nm LIDT and, for 355 nm HR stacks, a distinct lower-flow regime (~10 sccm).

Optics and optical instruments↗

DOE OSTI2020

In-Situ Helium Implantation and TEM Investigation of Radiation Tolerance to Helium Bubble Damage in Equiaxed Nanocrystalline Tungsten and Ultrafine Tungsten-TiC Alloy

The use of ultrafine and nanocrystalline materials is a proposed pathway to mitigate irradiation damage in nuclear fusion components. Here, we examine the radiation tolerance of helium bubble formation in 85 nm (average grain size) nanocrystalline-equiaxed-grained tungsten and an ultrafine tungsten-TiC alloy under extreme low energy helium implantation at 1223 K via in-situ transmission electron microscope (TEM). Helium bubble damage evolution in terms of number density, size, and total volume contribution to grain matrices has been determined as a function of He+ implantation fluence. The outputs were compared to previously published results on severe plastically deformed (SPD) tungsten implanted under the same conditions. Large helium bubbles were formed on the grain boundaries and helium bubble damage evolution profiles are shown to differ among the different materials with less overall damage in the nanocrystalline tungsten. Compared to previous works, the results in this work indicate that the nanocrystalline tungsten should possess a fuzz formation threshold more than one order of magnitude higher than coarse-grained tungsten.

36 MATERIALS SCIENCE↗

NASA NTRS1971

Damage and recovery characteristics of lithium-containing solar cells.

Damage and recovery characteristics were measured on lithium-containing solar cells irradiated by 1-MeV electrons. Empirical expressions for cell recovery time, diffusion-length damage coefficient immediately after irradiation, and diffusion-length damage coefficient after recovery were derived using results of short-circuit current, diffusion-length, and reverse-bias capacitance measurements. The damage coefficients were expressed in terms of a single lithium density parameter, the lithium gradient. A fluence dependence was also established, this dependence being the same for both the immediate-post-irradiation and post-recovery cases. Cell recovery rates were found to increase linearly with lithium gradient.

Faith, T. J.↗

NASA NTRS1972

The octahedral shear strain theory and its relation to biaxial cumulative fatigue damage.

The octahedral shear strain range concept is used in analyzing multiaxial fatigue damage. Limited test data from a two-step loading sequence show that the loading effect is still pronounced in the multiaxial case and that the relation between damage and cycle ratio is nonlinear. Among uniaxial cumulative damage concepts, the modified multiaxial double linear damage rule seems to show the most favorable experimental results.

Zamrik, S. Y.↗

NASA NTRS1972

Contamination damage avoidance concepts for propulsion feed system components.

The potential gain in the reliability of reusable long-term mission vehicles through the minimization of component damage due to the ingestion of particulate contamination by feed system components has been recognized by the NASA-LeRC and MDAC, and a program to investigate these problems has been completed. This investigation covered the determination of the cycle life of a typical 2-in. poppet type of shutoff valve in an uncontaminated GH2 environment and then compared this component performance with simulated operation with GN2 and LN2 containing controlled amounts of AL2O2 contaminant particles. The original valve design was tested for contamination damage tolerance characteristics under full flow and cyclic operating conditions, redesigned to improve the damage tolerance to contaminants and then retested. A second method of approach to damage tolerance control was investigated through the evaluation of various types of particulate separation devices. The study included various types of dynamic separators but did not cover conventional filter assemblies.

Endicott, D. L.↗

NASA NTRS1974

Some effects of applied stress on early stages of cavitation damage

The phenomenon of cavitation flow damage is discussed. The initial phases of damage and the effect of external stresses on the extent to which damage is incurred are analyzed. Three experimental facilities were used to procure the data required: (1) a water loop with venturi, (2) a mercury loop with venturi, and (3) a vibratory facility (stationary specimen, nonflow system). A description of each system is provided for the clarification of test conditions. Photographs of typical cavitation damage instances are included.

Kemppainen, D. J.↗

NASA NTRS1974

Satellite detection of vegetative damage and alteration caused by pollutants emitted by a zinc smelter

The author has identified the following significant results. Field observations and data collected by low flying aircraft were used to verify the accuracy of maps produced from the satellite data. Although areas of vegetation as small as six acres can accurately be detected, a white pine stand that was severely damaged by sulfur dioxide could not be differentiated from a healthy white pine stand because spectral differences were not large enough. When winter data were used to eliminate interference from herbaceous and deciduous vegetation, the damage was still undetectable. The analysis was able to produce a character map that accurately delineated areas of vegetative alteration due to high zinc levels accumulating in the soil. The map depicted a distinct gradient of less damage and alteration as the distance from the smelter increased. Although the satellite data will probably not be useful for detecting small acreages of damaged vegetation, it is concluded that the data may be very useful as an inventory tool to detect and delineate large vegetative areas possessing differing spectral signatures.

Mcmurtry, G. J.↗

NASA NTRS1975

Modeling damaged wings: Element selection and constraint specification

The NASTRAN analytical program was used for structural design, and no problems were anticipated in applying this program to a damaged structure as long as the deformations were small and the strains remained within the elastic range. In this context, NASTRAN was used to test three-dimensional analytical models of a damaged aircraft wing under static loads. A comparison was made of calculated and experimentally measured strains on primary structural components of an RF-84F wing. This comparison brought out two sensitive areas in modeling semimonocoque structures. The calculated strains were strongly affected by the type of elements used adjacent to the damaged region and by the choice of multipoint constraints sets on the damaged boundary.

Stronge, W. J.↗

NASA NTRS1975

Electron and proton damage coefficients in low-resistivity silicon

The electron and proton damage coefficients for low resistivity p-type boron-doped silicon were determined from minority-carrier lifetime measurements on bulk material and diffusion length measurements on solar cells. The bulk samples were irradiated with electrons at three energy levels (0.5, 1.5, and 2.5 MeV) using a Dynamitron. Lifetime measurements were made with a steady-state photoconductivity apparatus, and comparison measurements of diffusion length were obtained using the steady-state surface photovoltage method (Goodman, 1961). The diffusion-length damage coefficients increased with decreasing resistivity for boron-doped silicon; this dependence can be qualitatively accounted for using a two-level Hall-Shockley-Read model. The damage coefficients for solar cells were larger than for their bulk-material counterparts. The damage coefficient was apparently independent of the dislocation density in the 0.1 ohm-cm bulk samples and solar cells investigated.

Srour, J. R.↗

NASA NTRS1977

Image dissector photocathode solar damage test program

Image dissector sensors of the same type which will be used in the NASA shuttle star tracker were used in a series of tests directed towards obtaining solar radiation/time damage criteria. Data were evaluated to determine the predicted level of operability of the star tracker if tube damage became a reality. During the test series a technique for reducing the solar damage effect was conceived and verified. The damage concepts are outlined and the test methods and data obtained which were used for verification of the technique's feasibility are presented. The ability to operate an image dissector sensor with the solar image focussed on the photocathode by a fast optical lens under certain conditions is feasible and the elimination of a mechanical protection device is possible.

Smith, R. A.↗

NASA NTRS1977

Fatigue damage of notched boron/epoxy laminates under constant-amplitude loading

Fatigue damage in (0, plus or minus 45) and (0, plus or minus 45, 90) boron/epoxy laminates was studied with X-ray radiography and scanning electron microscopy. In addition, limited tests for residual strength and stiffness were performed. Initially, fatigue damage in both (0, plus or minus 45) and (0, plus or minus 45, 90) laminates occurred as intralaminar cracks around the edge of the hole. Then, whenever further damage developed, intralaminar cracks in the plus or minus 45-deg plies began to propagate from the edge of the hole. Finally, in both types of laminates, primarily plus or minus 45-deg fibers broke (prior to two-piece failure) where intralaminar cracks in the plus or minus 45-deg plies had occurred. In the (0, plus or minus 45) laminates, the 45-deg plies developed intralaminar and transthickness cracks along lines parallel to the loading axis and tangent to the hole in the test specimen. This damage, which was most pronounced under compressive loads, had little effect on either strength or stiffness. In contrast, in the (0, plus or minus 45, 90) laminates, the plus or minus 45-deg plies developed intralaminar cracks transverse to the loading axis.

Roderick, G. L.↗

NASA NTRS1978

Using reflectance and photography to detect ozone damage to cantaloupe plants

Laboratory and field reflectance measurements showed that ozone-damaged cantaloupe (Cucumis melo L.) leaves had lower water contents and higher reflectance than nondamaged leaves. Cantaloupe plants with lightly, severely, and very severely ozone-damaged leaves were distinguishable from nondamaged plants by reflectance measurements in the 1.35-2.5-micron near-IR water absorption band. Ozone-damaged leaf areas were detected photographically 16 hours before the damage was visible.

Gausman, H. W.↗

NASA NTRS1979

Dynamic response of damaged angleplied fiber composites

The effects of low level damage induced by monotonic load, cyclic load and/or residual stresses on the vibration frequencies and damping factors of fiber composite angleplied laminates were investigated. Two different composite systems were studied - low modulus fiber and ultra high modulus fiber composites. The results obtained show that the frequencies and damping factors of angleplied laminates made from low modulus fiber composites are sensitive to low level damage while those made from ultra high modulus composites are not. Vibration tests may not be sufficiently sensitive to assess concentrated local damage in angleplied laminates. Dynamic response determined from low-velocity impact coupled with the Fast Fourier Transform and packaged in a minicomputer can be a convenient procedure for assessing low-level damage.

Chamis, C. C.↗

NASA NTRS1980

Effects of moisture, residual thermal curing stresses and mechanical load on the damage development in quasi-isotropic laminates

Classical laminate theory and a finite element model were used to predict stress states prior to the first formation of damage in laminates fabricated from T/300/5208. Crack patterns characteristic of the laminate in a wet or dry condition were also predicted using a shear lag model. Development of edge damage was recorded and observed during the test by transferring an image of the damage from the edge surface on to a thin acetate sheet such that the damage imprinted could be immediately viewed on a microfiche card reader. Moisture was shown to significantly alter the interior and edge dry stress states due to swelling and a reduction of elastic properties and to reduce the transverse strength in 90 deg plies. A model was developed in order to predict changes in first ply failure laminate loads due to differences in stacking sequence together with a wet or dry environmental condition.

Kriz, R. D.↗

NASA NTRS1980

The potential for damage from the accidental release of conductive carbon fibers from aircraft composites

The paper considers the potential for damage from the accidental release of conductive carbon fibers from aircraft composites. The electrical conductivity of carbon and graphite fibers has led to electrical equipment damage from the inadvertent release of virgin fibers into the atmosphere; an accidental release of carbon fibers from filamentary composites from the burning of crashed commercial airliners could damage electrical and electronic equipment. The experimental and analytical results by NASA of the methods of assessing the extent of potential damage in terms of costs is presented; the NASA materials research program to provide alternate or modified composites to overcome electrical hazards of carbon composites in aircraft structures is described.

Bell, V. L.↗