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At least 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy

The third Sandia Fracture Challenge illustrated the geometric and material uncertainties presented by modern additive manufacturing techniques. Tasked with the challenge of predicting failure of a complex additively-manufactured geometry made of 316L stainless steel, we combined a rigorous material calibration scheme with a number of statistical assessments of problem uncertainties. Particularly, we used optimization techniques to calibrate a rate-dependent and anisotropic Hill plasticity model to represent material deformation coupled with a damage model driven by void growth and nucleation. Through targeted simulation studies we assessed the influence of internal voids and surface flaws on the specimens of interest in the challenge which guided our material modeling choices. Employing the Kolmogorov–Smirnov test statistic, we developed a representative suite of simulations to account for the geometric variability of test specimens and the variability introduced by material parameter uncertainty. This method allowed the team to successfully predict the failure mode of the experimental test population as well as the global response with a high degree of accuracy.

316L stainless steel↗
DOE OSTI2019

Axial Tensile Failure Analysis of SiC{sub f}/Ti Composite Based on Continuum Cohesive Zone Model

In this paper, the failure behavior of SiC fiber-reinforced Ti-6Al-4V matrix composite (SiC{sub f}/Ti) under longitudinal loads was studied experimentally and theoretically. Experimental results show that the interface of SiC{sub f}/Ti composite is continuous and integral. Through SEM observations, it was found that transverse matrix cracks initiated from the debonding region of the interface. A three-dimensional representative volume element was developed to simulate the failure process of SiC{sub f}/Ti-6Al-4V composite. A continuum cohesive zone model is employed to describe the debonding behavior at the interface, compared with a discrete one. More accurate simulated results were obtained by a continuum cohesive zone model, corresponding to experimental results. The transverse cracking behavior of the matrix was simulated. The stress–strain curves predicted by the continuum cohesive zone model show a good agreement with the experimental results. The fiber volume fraction, interface strength and interface toughness are investigated to exhibit their influences upon the longitudinal mechanical characteristics of SiC{sub f}/Ti-6Al-4V composite.

36 MATERIALS SCIENCE↗
DOE OSTI2021

An FEM-Based Peridynamic Model for Failure Analysis of Unidirectional Fiber-Reinforced Laminates

To predict the mixed damage modes of unidirectional fiber-reinforced polymer (FRP) laminates under dynamic loading, an FEM-based peridynamic model is introduced in this paper. Based on its geometric structure and material composition, a long fiber lamina is considered a transversely isotropic medium as a result of homogenization at the meso-scale. The laminated structure is modeled by stacking surface mesh layers with arbitrary fiber angles along the thickness direction. The peridynamic bonds between Gauss points connect the separated elements. These bonds are classified as inner-layer bonds and inter-layer bonds. To represent the anisotropy of a laminate, the micro-elastic modulus of the inner-layer and inter-layer bonds is calculated from the anisotropic engineering material constants separately. To capture complex failure behaviors of laminate structures, an empirical damage model is proposed for the tension/ compression breakage of peridynamic bonds. This damage model can control the in-plane and delamination failure process. Finally, benchmark tests are conducted to validate the elastic response of laminates under dynamic loading. In terms of damage analysis, the proposed model can capture the complex damage modes and resistive force of laminate structures.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Experimental investigation of probabilistic failure of SiC/SiC composite tubes under multiaxial loading

This paper presents an experimental investigation of the failure behavior of SiC fiber-reinforced SiC matrix (SiC/SiC) composite tubes under multiaxial loading. A new testing apparatus is designed to independently apply axial stress and internal pressure to SiC/SiC tubes. Acoustic emission (AE) is used to monitor the damage growth in the specimen. Based on the measured stress–strain response, a strain-based criterion is proposed to determine the proportional limit stress (PLS). The proposed strain-based criterion is compared with the PLS determined by the AE measurement. The PLS is determined for different loading ratios to form a multiaxial failure surface. By testing multiple replicates, the statistical variations of the PLS are determined. In conclusion, based on the experimental results, a mathematical model is developed to characterize the probability distribution of the PLS of SiC/SiC composites under multiaxial loading.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydrogen-enhanced compatibility constraint for intergranular failure in FCC FeNiCoCrMn high-entropy alloy

The fundamental mechanism of hydrogen embrittlement was investigated in the high-entropy alloy FeNiCoCrMn using slow strain rate tensile tests with and without internal hydrogen. Hydrogen induced intergranular failure and reduced the average grain elongation parallel to the tensile axis, but also increased the local plasticity within grains. Here, the influence of hydrogen on plasticity establishes a compatibility constraint across grain boundaries, which results in failure along the hydrogen-weakened grain boundaries. This study is the first to directly confirm the presence of the hydrogen-enhanced compatibility constraint in a high-entropy alloy and highlights the importance of developing a physical understanding of grain-scale interactions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Electrochemical-mechanical coupling failure mechanism of composite cathode in all-solid-state batteries

Composite cathode composed of active particles and solid electrolytes (SEs) can considerably enlarge the particle-SE contact areas and achieve high areal loadings in all-solid-state batteries (ASSBs). However, the challenging interfacial instability and particle damage problems remain unsolved. Herein, we establish a 3D electrochemical-mechanical coupled model to investigate the underlying failure mechanism by considering the governing electrochemical and physics processes. Micro-scale heterogeneous primary particles with random crystallographic orientation and size inside the LiNi 1/3 Co 1/3 Mn 1/3 O 2 (NCM111) secondary particle of the model result in the anisotropic Li diffusion and volume variation within the secondary particle, leading to significant nonuniformity of the Li concentration, and GPa-level stress distributions at primary particle boundaries, and finally causing the particle internal cracks. The particle volume shrinkage under the constraint of stiff Li 7 La 3 Zr 2 O 12 (LLZO) SE triggers the interface debonding (gap>50 nm) with increased interfacial impedance to degrade cell capacity. Higher C-rates result in larger residual stress (~100 MPa)/strain/debonding gap at dis-charging end, more likely to deteriorate the cell performance. Increasing the interfacial strength between the particle and SE can suppress the interface debonding but induces high stress (up to 10 GPa). In conclusion, results reveal the underlying mechanism of the electrochemical-mechanical coupling failure mechanism for composite cathode and provide promising guidance on the further improvement of a more robust composite cathode for ASSBs.

25 ENERGY STORAGE↗
DOE OSTI2022

Modeling deformation and failure in AlSi-polyester abradable sealcoating material using microstructure-based finite element simulation

A plasma-sprayed aluminum-silicon (AlSi)/polyester coating is applied in modern gas turbine engines as an abradable sealcoating to maintain tight clearances between the rotating blades and the static casing. While running the engine, the rotating blades “rub” with the abradable coating, which results in extreme strain rate (up to 10 6 ) dynamics and a high-temperature environment. Due to the difficulty of collecting direct measurements, predictive computational models are important for analyzing the deformation and failure of the abradable material, to help meet the design target of avoiding damage to the blade tip and maintaining high fuel efficiency. In this research, a microstructure-based finite element (FE) computational model was developed to capture the complex mechanical behavior of the AlSi/polyester microstructure. The model is based on a virtual representative-volume-element (RVE) of a metal-polymer microstructure, reconstructed from x-ray computed tomography. It models the plastic deformation of, and damage to, each AlSi and polyester constituents, as well as the failure at their interface. The model was calibrated and validated with uniaxial tension and compression experiments, conducted at two temperatures (298 K and 533 K) at an applied strain rate of 10 3 - 10 4 s -1 . The material exhibited strongly asymmetric tension-compression behavior and a sensitivity to temperature, which was well captured by the model. The model was further applied to investigate changes in mechanical behavior due to variations in constituents’ volume fractions, which provides guidance to the microstructural design of AlSi/polyester abradable materials. The model is expected to facilitate the development of improved abradable materials by bypassing the conventional trial-and-error approach and extensive testing requirements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Intergranular ductile failure of materials with plastically heterogeneous grains

In several precipitation hardened alloys that are susceptible to intergranular ductile failure, precipitation does not always occur uniformly throughout the microstructure, and regions close to grain boundaries may remain precipitate-free. These precipitate-free zones (PFZs) in the material microstructures result in plastically heterogeneous grains, since PFZs are expected to have lower yield strength but higher strain-hardenability compared to the precipitate containing grain interior. Experimentally, the presence of PFZs in precipitation-hardened alloys has been associated with both increase and decrease in materials’ ductility, with or without significant change in the strength. Thus, to understand and rationalize the experimental observations, we have carried out extensive microstructure-based finite element calculations of intergranular ductile failure in materials under tensile loading conditions. In the calculations, both the grain boundaries and PFZs are discretely modeled, and a wide range of the values of yield strength, strain-hardenability and width of PFZs in the material microstructures are analyzed. Our results show that the effects of PFZs on the overall mechanical response of the material strongly depend on the values of yield strength and strain-hardenability of PFZs. Here, there exists an optimum combination of the values of these two parameters that can result in the overall ductility and tensile strength of the material microstructures with PFZs being greater than the microstructures without PFZs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Micromechanical aspects of deformation and failure of advanced Iron-Chromium-Aluminum alloys

Here this work investigates the micromechanical deformation and failure mechanisms of advanced FeCrAl alloys developed for use in nuclear reactors as cladding material. Three different FeCrAl alloys (82-X)Fe-13Cr-5Al-X (X=Nb, TiC, 0 for base alloy) were investigated both in their as-received and welded states. In-situ neutron diffraction with simultaneous digital image correlation was used to determine micromechanical deformation mechanisms not only as a function of elemental composition but also as a condition of state (as-received vs. welded). Ex-situ X-ray computed tomography was used on as-deformed samples to help determine the failure mechanisms and void initiation strains.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Modeling interconnections of safety and financial performance of nuclear power plants, part 3: Spatiotemporal probabilistic physics-of-failure analysis and its connection to safety and financial performance

Here, this paper is a byproduct of a line of research by the authors to analyze interrelationships of safety and financial performance of nuclear power plants (NPPs). The result of this line of research is summarized in three parts: Part 1 covers a categorical review of relevant literature and the theoretical bases that support the methodological developments in Part 2. Part 2 introduces an Integrated Enterprise Risk Management (I-ERM) methodological framework to quantify the interconnections of safety and financial performance with a focus on operation and maintenance (O&M) of NPPs. Part 2 has also demonstrated the applicability and values of the I-ERM methodology through an NPP case study. This paper is Part 3, where detailed development and implementation of one of the I-ERM modules, i.e., probabilistic physics-of-failure (PPoF) analysis, and its connection with safety and financial performance is reported. In this article, the physical failure modeling for hardware components is advanced by incorporating finite element analysis (FEA) into PPoF analysis and coupling the FEA-based PPoF with the maintenance performance through a renewal process model. This article covers two scientific contributions: (i) first-of-its-kind incorporation of FEA into the PPoF model of thermal fatigue for NPP components; and (ii) advancing the interface between the PPoF analysis and the renewal process model in order to deal with spatiotemporal FEA outputs and to efficiently estimate the physical transition rates even when the PPoF outputs are dominated by success data. Through the incorporation of FEA, the resolution of the PPoF analysis is enhanced as spatiotemporal conditions such as stress and temperature can be considered explicitly instead of relying on simplified assumptions or analytical models with reduced spatiotemporal dimensions. To demonstrate an application of the FEA-based PPoF analysis and its coupling with maintenance through the renewal process model, a case study is conducted using excess letdown elbow piping in the chemical and volume control system of a Pressurized Water Reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Failure Modes of Platinized pn+-GaInP Photocathodes for Solar-Driven H2 Evolution

The long-term stability for the hydrogen-evolution reaction (HER) of homojunction pn+-Ga0.52In0.48P photocathodes (band gap = 1.8 eV) with an electrodeposited Pt catalyst (pn+-GaInP/Pt) has been systematically evaluated in both acidic and alkaline electrolytes. Electrode dissolution during chronoamperometry was correlated with changes over time in the current density-potential (J-E) behavior to reveal the underlying failure mechanism. Pristine pn+-GaInP/Pt photocathodes yielded an open-circuit photopotential (Eoc) as positive as >1.0 V vs the potential of the reversible hydrogen electrode (RHE) and a light-limited current density (Jph) of >12 mA cm-2 (1-sun illumination). However, Eoc and Jph gradually degraded at either pH 0 or pH 14. The performance degradation was attributed to three different failure modes: (1) gradual thinning of the n+-emitter layer due to GaInP dissolution in acid; (2) active corrosion of the underlying GaAs substrate at positive potentials causing delamination of the upper GaInP epilayers; and (3) direct GaAs/electrolyte contact compromising the operational stability of the device. This work reveals the importance of both substrate stability and structural integrity of integrated photoelectrodes toward stable solar fuel generation.

CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS,S↗
DOE OSTI2015

Seismic energy data analysis of Merapi volcano to test the eruption time prediction using materials failure forecast method (FFM)

The test of eruption time prediction is an effort to prepare volcanic disaster mitigation, especially in the volcano’s inhabited slope area, such as Merapi Volcano. The test can be conducted by observing the increase of volcanic activity, such as seismicity degree, deformation and SO2 gas emission. One of methods that can be used to predict the time of eruption is Materials Failure Forecast Method (FFM). Materials Failure Forecast Method (FFM) is a predictive method to determine the time of volcanic eruption which was introduced by Voight (1988). This method requires an increase in the rate of change, or acceleration of the observed volcanic activity parameters. The parameter used in this study is the seismic energy value of Merapi Volcano from 1990 – 2012. The data was plotted in form of graphs of seismic energy rate inverse versus time with FFM graphical technique approach uses simple linear regression. The data quality control used to increase the time precision employs the data correlation coefficient value of the seismic energy rate inverse versus time. From the results of graph analysis, the precision of prediction time toward the real time of eruption vary between −2.86 up to 5.49 days.

42 ENGINEERING↗
DOE OSTI2015

Two planar polishing methods by using FIB technique: Toward ultimate top-down delayering for failure analysis

Presently two major limiting factors are hindering the failure analysis (FA) development during the semiconductor manufacturing process and technology improvement: (1) Impossibility of manual polishing on the edge dies due to the amenability of layer peeling off; (2) Abundant demand of multi-locations FA, especially focusing different levels of layers simultaneously. Aiming at resolving these limitations, here we demonstrate two unique high precision polishing methods by using focused ion beam (FIB) technique. One is the vertical top down chemical etching at the aimed location; the other one is the planar top down slicing. Using the FIB for delayering not only solves these problems mentioned above, but also offers significant advantages over physical planar polishing methods such as: (1) having a better control of the delayering progress, (2) enabling precisely milling at a region of interest, (3) providing the prevention of over-delayering and (4) possessing capability to capture images at the region of interest simultaneously and cut into the die directly to expose the exact failure without damaging other sections of the specimen.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Failure of wooden sandwich beam reinforced with glass/epoxy faces

The mechanical properties and the failure of wooden beam strengthened with two faces from glass/epoxy composite and a wooden beam without strengthening was studied. Stresses and deflections on both beams, which are imposed in three point bending loading. On the idealized geometry of the specimens with detailed nonlinear orthotropic analysis was performed with a finite elements program. The failure study of the wooden beams was performed, applying the criterion of Tsai-Hill. The shear strength of the adhesive was taken into account. All the specimens were tested with three point bending loading and the experimental results were compared to those of the theoretical approach with the finite elements analysis. Comparing the results, the advantage of strengthened wooden beam against the simple wooden beam becomes obvious. Theoretical predictions were in good agreement with experimental results.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2016

Reactive flow modeling of small scale detonation failure experiments for a baseline non-ideal explosive

Small scale characterization experiments using only 1–5 g of a baseline ammonium nitrate plus fuel oil (ANFO) explosive are discussed and simulated using an ignition and growth reactive flow model. There exists a strong need for the small scale characterization of non-ideal explosives in order to adequately survey the wide parameter space in sample composition, density, and microstructure of these materials. However, it is largely unknown in the scientific community whether any useful or meaningful result may be obtained from detonation failure, and whether a minimum sample size or level of confinement exists for the experiments. In this work, it is shown that the parameters of an ignition and growth rate law may be calibrated using the small scale data, which is obtained from a 35 GHz microwave interferometer. Calibration is feasible when the samples are heavily confined and overdriven; this conclusion is supported with detailed simulation output, including pressure and reaction contours inside the ANFO samples. The resulting shock wave velocity is most likely a combined chemical-mechanical response, and simulations of these experiments require an accurate unreacted equation of state (EOS) in addition to the calibrated reaction rate. Other experiments are proposed to gain further insight into the detonation failure data, as well as to help discriminate between the role of the EOS and reaction rate in predicting the measured outcome.

42 ENGINEERING↗
DOE OSTI2019

The nature of catastrophic OLED lighting panel failure

Catastrophic failure due to electrical shorting is currently one of the key reliability challenges for commercial organic light emitting diode (OLED) solid-state lighting panels. Here, we explore the origin of panel-killing shorts through the use of a temperature-selective electroluminescence imaging technique that allows us to locate them early in their life cycle and study their growth over time. We identify two general classes of panel defect, termed bright spots and hot spots, which respectively originate from indium-tin-oxide agglomerations and microscale organic semiconductor dust particles on the substrate. The former are largely benign, whereas the latter can lead to local shunts that grow over time and cause catastrophic failure. We understand the growth process as a self-reinforcing cycle, where shunt-induced heating volatilizes the surrounding organic semiconductor, which in turn expands the shunt and leads to even more heating. Finally based on these results, we identify several practical strategies to arrest the growth of early-stage shorts or prevent them entirely, which could reduce the cost and improve the reliability of OLED lighting.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of grain size on damage and failure in two-phase materials: Homogenized CuPb

It is well known that spall failure strongly depends on the microstructure of a material. There have been numerous studies to study the effect of grain size on the overall spall strength and the total amount of damage in single element metals like copper. However, such systematic studies remain rare in two-phase materials and alloys. In this work, two incipient spall experiments were performed on a Cu–1%Pb alloy to understand the effect of grain size on the damage and failure in a two-phase material. Overall, these results showed that even though the spall strength did not change as a function of grain size, there were significant differences in the total amount of damage as a function of grain size. A clear increase in the total damage present in the material was seen as the grain size was increased from 32 to either 70 or 75 μm in either of the experiments. Furthermore, this difference was attributed to variations in the void growth rate as the grain size was increased.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Worldwide Physics-Based Lifetime Prediction of c-Si Modules Due to Solder-Bond Failure

Lifetime prediction of the fielded c-Si solar modules due to location-specific weather conditions has been an important topic of photovoltaic research and the economic viability of solar energy. Data analytic techniques such as the performance ratio method, Statistical clear sky model, and Suns-Vmp methods quantify the degradation from measured data of a solar farm, however, the nonlinear time-dependence and correlated degradations make it difficult to use the empirical degradation rates for ultimate lifetime projection. In this article, we propose a complementary physics-based model to predict the solder bond failure caused by mechanical stress associated with the variations of the temperature. Integrating the worldwide weather information from NASA/NSRDB databases, the model predicts the location-specific output-power degradation and the lifetime of a module due to solder bond failure. The model parameters are calibrated against qualification tests involving thermal cycling of specific batches of modules from a specific technology/manufacturer. The results may be summarized as: 1) Modules installed at higher latitudes show a longer lifetime due to reduced damage accumulation. 2) The reduction of temperature fluctuation close to large bodies of water, such as seashores, increases solder bond lifetime significantly. 3) Relatively speaking, modules installed close to the Tropic of Cancer/Capricorn (23.5 degrees North/South) suffer from a higher solder bond damage and have a shorter lifetime, suggesting a conservative design. This model should serve as a building block of a comprehensive reliability framework that can predict the lifetime of a module that experiences simultaneous and correlated degradation mechanisms involving yellowing, corrosion, and potential-induced degradation.

14 SOLAR ENERGY↗