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At least 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing

Abstract Residual stresses affect the performance and reliability of most manufactured goods and are prevalent in casting, welding, and additive manufacturing (AM, 3D printing). Residual stresses are associated with plastic strain gradients accrued due to transient thermal stress. Complex thermal conditions in AM produce similarly complex residual stress patterns. However, measuring real-time effects of processing on stress evolution is not possible with conventional techniques. Here we use operando neutron diffraction to characterize transient phase transformations and lattice strain evolution during AM of a low-temperature transformation steel. Combining diffraction, infrared and simulation data reveals that elastic and plastic strain distributions are controlled by motion of the face-centered cubic and body-centered cubic phase boundary. Our results provide a new pathway to design residual stress states and property distributions within additively manufactured components. These findings will enable control of residual stress distributions for advantages such as improved fatigue life or resistance to stress-corrosion cracking.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

This is the final report for the NASA funded project entitled "Crack Growth Prediction Methodology for Multi-Site Damage." The primary objective of the project was to create a capability to simulate curvilinear fatigue crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage. The second objective was to validate the capability by way of comparisons to experimental results. Both objectives have been achieved and the results are detailed herein. In the first part of the report, the crack tip opening angle (CTOA) fracture criterion, obtained and correlated from coupon tests to predict fracture behavior and residual strength of built-up aircraft fuselages, is discussed. Geometrically nonlinear, elastic-plastic, thin shell finite element analyses are used to simulate stable crack growth and to predict residual strength. Both measured and predicted results of laboratory flat panel tests and full-scale fuselage panel tests show substantial reduction of residual strength due to the occurrence of multi-site damage (MSD). Detailed comparisons of n stable crack growth history, and residual strength between the predicted and experimental results are used to assess the validity of the analysis methodology. In the second part of the report, issues related to crack trajectory prediction in thin shells; an evolving methodology uses the crack turning phenomenon to improve the structural integrity of aircraft structures are discussed, A directional criterion is developed based on the maximum tangential stress theory, but taking into account the effect of T-stress and fracture toughness orthotropy. Possible extensions of the current crack growth directional criterion to handle geometrically and materially nonlinear problems are discussed. The path independent contour integral method for T-stress evaluation is derived and its accuracy is assessed using a p- and hp-version adaptive finite element method. Curvilinear crack growth is simulated in coupon tests and in full-scale fuselage panel tests. Both T-stress and fracture toughness orthotropy are found to be essential to predict the observed crack paths. The analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically while insuring continuous airworthiness. Consequently, it will improve the technology to support the safe operation of the current aircraft fleet as well as the design of more damage-tolerant aircraft for the next generation fleet.

Chen, Chuin-Shan↗
NASA NTRS1994

Stable tearing behavior of a thin-sheet material with multiple cracks

Fracture tests were conducted on 2.3mm thick, 305mm wide sheets of 2024-T3 aluminum alloy with 1-5 collinear cracks. The cracks were introduced (crack history) into the specimens by three methods: (1) saw cutting; (2) fatigue precracking at a low stress range; and (3) fatigue precracking at a high stress range. For the single crack tests, the initial crack history influenced the stress required for the onset of stable crack growth and the first 10mm of crack growth. The effect on failure stress was about 4 percent or less. For the multiple crack tests, the initial crack history was shown to cause differences of more than 20 percent in the link-up stress and 13 percent in failure stress. An elastic-plastic finite element analysis employing the Crack Tip Opening Angle (CTOA) fracture criterion was used to predict the fracture behavior of the single and multiple crack tests. The numerical predictions were within 7 percent of the observed link-up and failure stress in all the tests.

Dawicke, D. S.↗
NASA NTRS1994

Influence of crack history on the stable tearing behavior of a thin-sheet material with multiple cracks

Fracture tests were conducted on 2.3mm thick, 305mm wide sheets of 2024-T3 aluminum alloy with from one to five collinear cracks. The cracks were introduced (crack history) into the specimens by three methods: saw cutting, fatigue precracking at a low stress range, and fatigue precracking at a high stress range. For the single crack tests, the initial crack history influenced the stress required for the onset of stable crack growth and the first 10mm of crack growth. The effect on failure stress was about 4 percent or less. For the multiple crack tests, the initial crack history was shown to cause differences of more than 20 percent in the link-up stress and 13 percent in failure stress. An elastic-plastic finite element analysis employing the CTOA fracture criterion was used to predict the fracture behavior of the single and multiple crack tests. The numerical predictions were within 7 percent of the observed link-up and failure stress in all the tests.

Dawicke, D. S.↗
NASA NTRS2000

Crack Turning in Integrally Stiffened Aircraft Structures

Current emphasis in the aircraft industry toward reducing manufacturing cost has created a renewed interest in integrally stiffened structures. Crack turning has been identified as an approach to improve the damage tolerance and fail-safety of this class of structures. A desired behavior is for skin cracks to turn before reaching a stiffener, instead of growing straight through. A crack in a pressurized fuselage encounters high T-stress as it nears the stiffener--a condition favorable to crack turning. Also, the tear resistance of aluminum alloys typically varies with crack orientation, a form of anisotropy that can influence the crack path. The present work addresses these issues with a study of crack turning in two-dimensions, including the effects of both T-stress and fracture anisotropy. Both effects are shown to have relation to the process zone size, an interaction that is central to this study. Following an introduction to the problem, the T-stress effect is studied for a slightly curved semi-infinite crack with a cohesive process zone, yielding a closed form expression for the future crack path in an infinite medium. For a given initial crack tip curvature and tensile T-stress, the crack path instability is found to increase with process zone size. Fracture orthotropy is treated using a simple function to interpolate between the two principal fracture resistance values in two-dimensions. An extension to three-dimensions interpolates between the six principal values of fracture resistance. Also discussed is the transition between mode I and mode II fracture in metals. For isotropic materials, there is evidence that the crack seeks out a direction of either local symmetry (pure mode I) or local asymmetry (pure mode II) growth. For orthotropic materials the favored states are not pure modal, and have mode mixity that is a function of crack orientation.

Pettit, Richard Glen↗
NASA NTRS1983

Internal and edge cracks in a plate of finite width under bending

Internal and edge cracks were studied by using Reissner's transverse shear theory. The effect of stress-free boundaries on the stress intensity factors in plates under bending were investigated. Among the results found, particularly interesting are those relating to the limiting cases of the crack geometries. The numerical results are given for a single internal crack, two collinear cracks, and two edge cracks. The effect of Poisson's ratio on the stress intensity factors was studied.

Boduroglu, H.↗
NASA NTRS1983

Internal and edge cracks in a plate of finite width under bending

In this paper the title problem is studied by using Reissner's transverse shear theory. The main purpose of the paper is to investigate the effect of stress-free boundaries on the stress intensity factors in plates under bending. Among the results found particularly interesting are those relating to the limiting cases of the crack geometries. The numerical results are given for a single internal crack, two collinear cracks, and two edge cracks. Also studied is the effect of Poisson's ratio on the stress intensity factors.

Boduroglu, H.↗
NASA NTRS1977

The thyroid and environmental stress in mammals

The effects of hyperoxia at ambient pressure on thyroid function and thyroid hormone metabolism have been assessed. Thyroidal activity was depressed in mice and rats by exposure to hyperoxia, due at least in part to a decrease in the rate of secretion of pituitary thyrotropin. The effects of hyperoxia on the peripheral deiodination of thyroxine were dependent on the concentration of oxygen employed and/or the duration of exposure. When significant changes were observed a reduction in the rate of deiodination and in the deiodinative clearance of T sub 4 occurred. Hyperoxia also resulted in a marked fall in circulating T sub 4 concentration and a decrease in T sub 4-binding activity in serum. Many of these effects of hyperoxia were prevented by the concomitant administration of large amounts of Vitamin E. These decreases in thyroid function and T sub 4 metabolism were associated with a decrease in the rate of whole body oxygen consumption. It was concluded that the deleterious effects of oxygen in the rat were not due to an oxygen induced hyperthyroid state in the peripheral tissues. Thyroxine was shown to be essential for survival during acute cold stress.

Galton, V. A.↗
DOE OSTI2025

ASSESSING THE EFFECTIVENESS OF ULTRASONIC IMPACT TREATMENT ON RESIDUAL STRESS PROFILES IN DISSIMILAR WELDED JOINTS

Residual stresses (RS) induced during welding processes are a critical concern in materials engineering, as they can significantly impair the mechanical performance of components by reducing fatigue strength and tensile load capacity. This challenge is especially pronounced in dissimilar metal welds (DMWs), where variations in thermal expansion properties between the joined alloys exacerbate the formation of tensile RS. Conventional post-weld heat treatments, though effective for homogeneous materials, often require substantial energy, specialized equipment, and extensive processing time, making them less practical for DMW applications. Thus, there is a clear need for innovative, energy-efficient techniques to mitigate these detrimental stresses. This study investigates ultrasonic impact treatment (UIT) as a possible alternative for mitigating tensile RS in both similar and dissimilar metal welds. To evaluate UIT’s effectiveness, neutron diffraction (ND) was employed as a nondestructive technique to quantify RS in three orthogonal directions—longitudinal, transverse, and normal. The results showed that UIT significantly reduced peak tensile RS, particularly in the longitudinal direction, by up to 180 MPa in similar welds and up to 150 MPa in dissimilar welds. Given the limited literature on UIT application in DMWs, this work contributes valuable data on stress redistribution mechanisms and highlights UIT’s potential as a practical stress-relief method. The findings lay the groundwork for further investigations aimed at optimizing process parameters and understanding long-term performance in welded joints.

EisaZadeh, Hamid [Western Carolina University, Cul↗
DOE OSTI2021

Effect of the Addition of a Low Equivalent Stress Mechanism to the Analysis of Geomechanical Behavior of the SPR West Hackberry Site

Sandia National Laboratories has long used the Munson-Dawson (M-D) model to predict the geomechanical behavior of salt caverns used to store oil at the Strategic Petroleum Reserve (SPR). Salt creep causes storage caverns to deform inward, thus losing volume. This loss of volume affects the salt above and around the caverns, puts stresses and strains on borehole casings, and creates surface subsidence which affects surface infrastructure. Therefore, accurate evaluation of salt creep behavior drives decisions about cavern operations. Parameters for the M-D model are typically fit against laboratory creep tests, but nearly all historic creep tests have been performed at equivalent stresses of 8 MPa or higher. Creep rates at lower equivalent stresses are very slow, such that tests take months or years to run, and the tests are sensitive to small temperature perturbations (<0.1°C). A recent collaboration between US and German researchers, recently characterized the creep behavior at low equivalent (deviatoric) stresses (<8 MPa) of salt from the Waste Isolation Pilot Plant. In addition, the M-D model was recently extended to include a low stress creep “mechanism”. This paper details new simulations of SPR caverns that use this extended M-D model, called the M-D Viscoplastic model. The results show that the inclusion of low stress creep significantly alters the prediction of steady-state cavern closure behavior and indicate that low stress creep is the dominant displacement mechanism at the dome scale. The implications for evaluating cavern and well integrity are demonstrated by investigating three phenomena: the extent of stress changes around the cavern; the predicted vertical strains applied to wellbore casings; and the evaluation of oscillating stress changes around the cavern due to oil sale cycles and their potential effect on salt fatigue.

58 GEOSCIENCES↗
NASA NTRS2017

Contribution of Sub-Mesoscales to the Vertical Velocity: The Omega-Equation

The oceans ability to regulate carbon dioxide depends on biogeochemical processes that are influenced strongly by eddies. Eddy-resolving simulations have shown that sub-mesoscales (SM) (110 km) generate the highest magnitude vertical velocity and that mesoscales (M) also enhance their contribution to the vertical velocity but to a lesser extent. In this study, we consider the question: can analogous results be obtained using the less numerically demanding -equation? Previously, this question has not been answered because of two reasons: 1) the canonical Hoskins form of the - equation does not include the buoyancy vertical fluxes caused by M and SM; and 2) Giordani et al. (2016) showed how to include an arbitrary vertical buoyancy flux, but no parameterizations were available for the M and SM vertical fluxes. How- ever, the latter are now available together with their assessments, so we consider SM because they make the largest contribution to the vertical velocity. The resulting vertical velocity depends on the extent of the SM regime, the horizontal buoyancy gradient (representing baroclinic instabilities), and the SM eddy kinetic energy. The vertical velocity depends in a linear manner on the wind stress and it may exhibit seasonal variations. The wind stress has two effects on the -equation: indirectly via its contribution to the sub-mesoscale buoyancy flux and directly through the wind stress itself. The results of our sensitivity analysis highlight the range of SM-induced vertical velocities obtained using different input data.

oceans↗
NASA NTRS1980

Photogeological constraints on lunar and planetary vulcanism, part 2

The use of several simple theoretical modelling approaches in simulating lava erosion were evaluated. Both one dimensional and two dimensional models were used with the two dimensional model being superior. The two dimensional model accounts, in a purely phenomenological way, for the effects of turbulence and mechanical erosion in a flow. Criteria for mechanical erosion was related to the basal stress and the effect of entrained eroded material on fluid properties was parameterized.

Source record↗
NASA NTRS1988

Anisotropic constitutive modeling for nickel base single crystal superalloys using a crystallographic approach

A micromechanical model based on crystallographic slip theory was formulated for nickel-base single crystal superalloys. The current equations include both drag stress and back stress state variables to model the local inelastic flow. Specially designed experiments have been conducted to evaluate the effect of back stress in single crystals. The results showed that (1) the back stress is orientation dependent; and (2) the back stress state variable in the inelastic flow equation is necessary for predicting anelastic behavior of the material. The model also demonstrated improved fatigue predictive capability. Model predictions and experimental data are presented for single crystal superalloy Rene N4 at 982 C.

Stouffer, D. C.↗
NASA NTRS1991

A model of the formation of high-salinity shelf water on polar continental shelves

This study presents a model of the flow and salinity fields forced by sea-surface salinity flux and wind stress curl and examines the processes that create High-Salinity Shelf Water (HSSW). To investigate the relative effects of wind stress and buoyancy forcing in HSSW production, the polynya freezing rate in the model is varied from 0.0 to 0.30 m/d, and the Ekman pumping derived from the wind stress curl is varied independently from 0.0 to 1.8 x 10 exp 6 m/s. The Ekman pumping was found to control the magnitude of the circulation, while the polynya freezing rate controlled the extent of salinization in the shelf water. The flux of HSSW increases linearly with increasing Ekman pumping above 0.3 x 10 exp -6 m/s. The modeled flux of HSSW and the flux of derived Botttom Water for the present estimates of the forcings (a peak freezing rate of 0.10 m/d and Ekman pumping of 0.2 x 10 exp -6 m/s) agree with the fluxes inferred from physical and chemical observations in the deep Weddel Sea by oceanographic field programs.

Grumbine, Robert W.↗
NASA NTRS2019

Prenatal 2g Exposure Alters Placental Expression of Stress-Related Genes

Extra-terrestrial colonization is of growing interest to space agencies and private entities, emphasizing the importance of research on reproduction and development in the absence of Earth's 1G. Maternal stressors can modify offspring development, exerting significant lifespan and crossgenerational changes through prenatal programming. The space environment is stressful, therefore exposure to altered gravity during pregnancy may impact later life outcomes in offspring. In ground-based studies, we exposed pregnant rats to continuous +G (above Earth gravity), and observed overweight and elevated anxiety in adult male (but not female) offspring, common phenotypes associated with prenatal maternal stress. Here we hypothesize that exposure to increased gravity during pregnancy elicits changes in the expression of stress-related genes in placenta that may mediate emergence of later life outcomes. While the placenta transports maternal factors to the fetus and produces endogenous fetal hormones, stress-induced changes at the placental-uterine interface may also alter communication between mother and fetus, facilitating prenatal transmission of unfavorable later life outcomes and cross-generational epigenetic alterations. Maternal stress elevates maternal glucocorticoids however placental 11b-hydroxysteroid dehydrogenase type 2 (HSD11B2) buffers fetal exposure by converting cortisol/corticosterone into inactive metabolites. Maternal stress during pregnancy down-regulates this enzyme and can induce epigenetic changes in placental and fetal tissues accounting for heightened adult HPA reactivity. Past studies have shown a placenta-specific increase in DNA methyltransferase (DNMT3a) mRNA in stressed mothers, an effect with implications for genome-wide epigenetic changes that may account for diverse phenotypic outcomes following maternal stress. Here we exposed groups of pregnant rats to one of five gravity loads (1, 1.5, 1.75 and 2G) and analyzed placental samples during late gestation. We predicted a systematic dose-response relationship between gravity load and the expression of the HSD11B2 and DNMT3 genes, thereby linking maternal exposure to altered gravity during pregancy with maternal stress.

Kalotia, Simranjit K.↗
NASA NTRS1998

Residual Stresses Modeled in Thermal Barrier Coatings

Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We examined the effect on stress during burner rig thermal cycling of the following independent variables: creep in the bond coat and top coat, oxidation, bond coat coefficient of thermal expansion, number of thermal cycles, and interfacial roughness. All these factors were suspected of influencing TBC failure. The model showed that all the material properties studied had a significant effect on the coating's residual stresses if the interface of the bond coat was rough. Bond coat expansion, bond coat oxidation, and bond coat creep had the highest effect on coating stresses, and these were highly interactive. The model also showed that the mechanism of stress generation during thermal cycling changed with the number of thermal cycles. Bond coat and top coat creep dominated stress generation during early thermal cycles, greatly increasing delamination stresses at the peaks of the bond coat. Therefore, creep is the prime driver for delamination cracking early in life, but cracking is limited to the bond coat peak region. Oxidation of the bond coat, on the other hand, tended to dominate stress generation during later cycles by greatly increasing delamination stresses over bond coat valleys. These results indicate that oxidation is the driver for the continued cracking necessary to cause ceramic layer spallation.

Freborg, A. M.↗
NASA NTRS1984

Objective measure of pilot workload

Timesharing behavior in a data-entry task, similar to a pilot entering navigation data into an on-board computer is investigated. Auditory reaction time as a function of stimulus information and dimensionality is examined. This study has direct implications for stimulus selection for secondary tasks used in the GAT flight simulator at Ames Research Center. Attenuation effects of heat and cold stress in a psychological refractory period task were studied. The focus of interest is the general effects of stress on attention rather than upon specific temperature related phenomena.

Kantowitz, B. H.↗
DOE OSTI2024

Effect of cold-cap-bottom shear stress on primary foam stability

Here, we analyze the heat transfer between the melt pool and the layer of reacting materials called cold cap, which is the determining factor for the glass production rate in Joule-heated air-bubbled nuclear waste glass melters. We consider the effects of bubbling rate, melt viscosity, melt thermal conductivity, conversion kinetics, and shear rate at the cold-cap bottom, and develop simple relationships for the cold-cap bottom temperature and glass production rate. We show that the melt convection enhances the heat transfer to the cold cap by suppressing the thermal boundary layer and primary foam, while the conversion kinetics opposes these effects. Additionally, we mention how dissolving silica particles affects the primary foam stability and discuss the limitations of the presented approach for vigorously foaming feeds.

36 MATERIALS SCIENCE↗