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At least 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Experimental Evaluation of Fatigue Crack Initiation from Corroded Hemispherical Notches in Aerospace Structural Materials

A test program was developed and executed to evaluate the influence of corroded hemispherical notches on the fatigue crack initiation and propagation in aluminum 7075-T7351, 4340 steel, and D6AC steel. Surface enhancements such as shot peening and laser shock peening were also incorporated as part of the test effort with the intent of improving fatigue performance. In addition to the testing, fracture mechanics and endurance limit based analysis methods were evaluated to characterize the results with the objective of challenging typical assumptions used in modeling fatigue cracks from corrosion pits. The results specifically demonstrate that the aluminum and steel alloys behave differently with respect to fatigue crack initiation from hemispherical corrosion pits. The aluminum test results were bounded by the fracture mechanics and endurance limit models while exhibiting a general insensitivity to the residual stress field generated by shot peening. The steel specimens were better characterized by the endurance limit fatigue properties and did exhibit sensitivities to residual stresses from the shot peening and laser shock peening

Garcia, Daniel B.↗
NASA NTRS2012

STS-133/ET-137 Tanking Test Photogrammetry Assessment

Following the launch scrub of Space Shuttle mission STS-133 on November 5, 2010, an anomalous condition of cracked and raised thermal protection system (TPS) foam was observed on the External Tank (ET). Subsequent dissection of the affected TPS region revealed cracks in the feet of two Intertank (IT) metallic stringers. An extensive investigation into the cause(s) and corrective action(s) for the cracked stringers was initiated, involving a wide array of material and structural tests and nondestructive evaluations, with the intent to culminate into the development of flight rational. One such structural test was the instrumented tanking test performed on December 17, 2010. The tanking test incorporated two three-dimensional optical displacement measurement systems to measure full-field outer surface displacements of the TPS surrounding the affected region that contained the stringer cracks. The results showed that the radial displacement and rotation of the liquid oxygen (LO2) tank flange changed significantly as the fluid level of the LO2 approached and passed the LO2 tank flange.

Oliver, Stanley T.↗
DOE OSTI2023

Results of FY 2023 Alloy 617 and Alloy 709 High-Temperature Crack-Growth Testing

This report summarizes the work performed at Idaho National Laboratory under the “Creep, fatigue and creep-fatigue crack growth tests” task of the “Long-Term VHTR Material Qualification – INL” work package. Work was performed this year to validate the crack growth monitoring setup used with the test frames against both continuous crack length monitoring using an optical camera, as well as post-mortem analysis of marker bands on the fracture surface. Delays prevented the use of a gauge to measure load-line displacement for early tests, and so the creep-fatigue crack growth setup was evaluated using the actuator displacement for a load-line displacement setup. While not ideal, this allowed examination of the shortcomings with the current software setup that was originally designed for performing stress corrosion crack growth rate studies. The method for data collection was modified to link the crack growth monitoring software with Instron’s Wave Matrix software. Once the load-line displacement gauge arrived, the crack growth equipment was successfully modified to permit continuous monitoring of both load-line displacement and crack length. This is critical for creep-fatigue and creep crack growth rate studies for ductile material, as it permits the C* and Ct analyses. Test results are shown for Alloy 617 fatigue and creep-fatigue (without the gauge for load-line displacement measurements), as well as creep-fatigue of Alloy 709, which was performed with the completed test setup, allowing for crack length and load-line displacement monitoring.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Multi‐Scale Model‐Informed Deep Learning for Plasma‐Nanoparticle Interaction

The Overarching Goal of this proposed research is to understand and quantitively determine the interactions between non-thermal plasma (hot electrons, reactive radicals, vibrationally excited species) and surface reactions on influencing the activity and selectivity of the desired reactions via developing multi-scale model informed deep learning algorithm. Investigating non-thermal plasma-surface interaction is feasible due to the low bulk temperature in the discharge region. To investigate the role of plasma-nanoparticle interaction on enhancing the reaction kinetics, we will focus on ammonia cracking to generate clean hydrogen over earth-abundant, non-critical metallic nanoparticles, which is of great significance for decarbonization. We hypothesize that (1) reactive radicals interacting with surface reaction species via Eley–Rideal mechanism will significantly lower the energetics of the potential rate-limiting step of nitrogen formation; (2) the surface will be charged heterogeneously under non-thermal plasma conditions and the charged site will lower the energetics of ammonia cracking through Langmuir– Hinshelwood mechanism; (3) vibrationally excited ammonia will further promote the initial N-H bond cleavage. To access the hypothesis, we will (1) reveal the surface charge effects on tunning the reaction energetics via interpretable, physics-informed deep learning accelerated density functional theory (DFT) calculations; (2) determine the reactive radicals interacting with surface reaction species on tuning the reaction energetics via DFT; (3) reveal the surface charge effects on tunning the reaction energetics via DFT and deep learning models, (4) quantify how vibrationally excited species, reactive radicals, and surface charging effects on enhancing the catalysis via developing DFT-based microkinetic modeling (MKM) and active learning. Deep and active learning of plasma-nanoparticle interactions effects on enhancing ammonia cracking to generate hydrogen represents a new paradigm for designing high performance plasma materials. The fundamental science of how plasma-nanoparticle interactions will change the plasma kinetics and will improve the energy efficiency for decarbonization and sustainability. The interpretable and physics-informed machine learning model will accelerate low temperature plasma chemistry and material discovery with physics rules and model interpretation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2014

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

This paper describes the results of a research program conducted to improve the understanding of fatigue crack growth rate behavior in the threshold growth rate region and to answer a question on the validity of threshold region test data. The validity question relates to the view held by some experimentalists that using the ASTM load shedding test method does not produce valid threshold test results and material properties. The question involves the fanning behavior observed in threshold region of da/dN plots for some materials in which the low R-ratio data fans out from the high R-ratio data. This fanning behavior or elevation of threshold values in the low R-ratio tests is generally assumed to be caused by an increase in crack closure in the low R-ratio tests. Also, the increase in crack closure is assumed by some experimentalists to result from using the ASTM load shedding test procedure. The belief is that this procedure induces load history effects which cause remote closure from plasticity and/or roughness changes in the surface morphology. However, experimental studies performed by the authors have shown that the increase in crack closure is a result of extensive crack tip bifurcations that can occur in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the fanning behavior which occurs in aluminum alloys is a function of intrinsic dislocation property of the alloy, and therefore, the fanned data does represent the true threshold properties of the material. However, for the corrosion sensitive steel alloys tested in laboratory air, the occurrence of fanning results from fretting corrosion at the crack tips, and these results should not be considered to be representative of valid threshold properties because the fanning is eliminated when testing is performed in dry air.

Forman, R. G.↗
NASA NTRS1994

Orientation effects on the measurement and analysis of critical CTOA in an aluminum alloy sheet

Fracture tests were conducted on 76.2mm wide, 2.3mm thick middle crack tension (M(T)) specimens machined from 2024-T3 aluminum sheet. The specimens were tested on the T-L orientation and comparisons were made to similar tests conducted in the L-T orientation. Measurement of critical crack tip opening angle (CTOA), applied stress, and crack front shape were made as a function of crack extension. A two-dimensional, elastic-plastic finite element analysis was used to simulate the fracture behavior for both orientations. The results indicate that the T-L orientation had a 10 percent lower stress at fracture than similar tests conducted in the L-T orientation. Correspondingly, the critical CTOA in the T-L tests reached a constant value of 4.7 degrees after 2-3mm of crack extension and the L-T tests reached a value of 6 degrees. The fracture surfaces of the T-L specimens were observed to remain flat, while those of the L-T specimens transitioned to a 45 degree slant fracture after about 2-3mm of crack extension. The tunneling behavior of the two orientations also differed; the T-L specimens reached a deeply tunneled stabilized crack front shape while, the L-T specimens were observed to have only a small amount of tunneling once the crack began to grow on the 45 degree slant. The two-dimensional, elastic-plastic finite element analysis was able to simulate the fracture behavior for both the T-L and L-T orientations.

Sutton, M. A.↗
DOE OSTI2022

Assessing Long-Term Cycling Stability of Single-Crystal Versus Polycrystalline Nickel-Rich NCM in Pouch Cells with 6 mAh cm -2 Electrodes

Lithium-ion batteries based on single-crystal LiNi1-x-yCoxMnyO2 (NCM, 1-x-y ≥ 0.6) cathode materials are gaining increasing attention due to their improved structural stability resulting in superior cycle life compared to batteries based on polycrystalline NCM. However, an in-depth understanding of the less pronounced degradation mechanism of single-crystal NCM is still lacking. Here, a detailed postmortem study is presented, comparing pouch cells with single-crystal versus polycrystalline LiNi 0.60 Co 0.20 Mn 0.20 O 2 (NCM622) cathodes after 1375 dis-/charge cycles against graphite anodes. The thickness of the cation-disordered layer forming in the near-surface region of the cathode particles does not differ significantly between single-crystal and polycrystalline particles, while cracking is pronounced for polycrystalline particles, but practically absent for single-crystal particles. Transition metal dissolution as quantified by time-of-flight mass spectrometry on the surface of the cycled graphite anode is much reduced for single-crystal NCM622. Similarly, CO 2 gas evolution during the first two cycles as quantified by electrochemical mass spectrometry is much reduced for single-crystal NCM622. Benefitting from these advantages, graphite/single-crystal NMC622 pouch cells are demonstrated with a cathode areal capacity of 6 mAh cm -2 with an excellent capacity retention of 83% after 3000 cycles to 4.2 V, emphasizing the potential of single-crystalline NCM622 as cathode material for next-generation lithium-ion batteries.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗
NASA NTRS1987

Tribological properties of coal slurries

A pin-on-disk tribometer was used to study the tribological properties of methyl alcohol-coal slurries. Friction coefficients, steel pin wear rates and wear surface morphological studies were conducted on AISI 440C HT and M-50 bearing steels which were slid dry and in solutions of methyl alcohol, methyl alcohol-fine coal particles, and methyl alcohol-fine coal particles-flocking additive. The latter was an oil derived from coal and originally intended to be added to the coal slurry to improve the sedimentation and rheology properties. The results of this study indicated that the addition of the flocking additive to the coal slurry markedly improved the tribological properties, especially wear. In addition, the type of steel was found to be very important in determining the type of wear that took place. Cracks and pits were found on the M-50 steel pin wear surfaces that slid in the coal slurries while 440C HT steel pins showed none.

Fusaro, Robert L.↗
DOE OSTI2022

Mechanical joint performances of friction self-piercing riveted carbon fiber reinforced polymer and AZ31B Mg alloy

Carbon fiber reinforced polymer (CFRP) and AZ31B Mg alloy were joined by the friction self-piercing riveting (F-SPR) with different steel rivet shank sizes. With the increase of rivet shank size, lap shear fracture load and mechanical interlock distance increased. Ultrafine grains were formed at the joint in AZ31B as a result of dynamic recrystallization, which contributed to the higher hardness. Fatigue life of the CFRP-AZ31B joint was studied at various peak loads of 0.5, 1, 2, and 3 kN and compared with the resistance spot welded AZ31B-AZ31B from the open literature. The fatigue performance was better at higher peak load (>2 kN) and comparable to that of resistance spot welding of AZ31B to AZ31B at lower peak loads (<1 kN). From fractography, the crack initiation for lower peak load (<1 kN) case was observed at the fretting positions on the top and bottom surfaces of AZ31B sheet. When peak load was increased, fretting between the rivet and the top of AZ31B became more dominant to initiate a crack during fatigue testing.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Ab Initio Molecular Dynamics Insights into Stress Corrosion Cracking and Dissolution of Metal Oxides

Oxide phases such as α-Fe2O3 (hematite) and α-Al2O3 (corundum) are highly insoluble in water; however, subcritical crack growth has been observed in humidity nonetheless. Chemically induced bond breaking at the crack tip appears unlikely due to sterically hindered molecular transport. The molecular mechanics of a crack in corundum with a reactive force field reveal minimal lattice trapping, leading to bond breaking before sufficient space opens for water transport. To address this, we model a pre-built blunt crack with space for H2O molecule adsorption at the tip and show that it reduces fracture toughness by lowering the critical J-integral. Then, we explore stress-enhanced dissolution to understand the mechanism of crack tip blunting in the oxide/water system. Density functional theory combined with metadynamics was employed to describe atomic dissolution from flat hematite and corundum surfaces in pure water. Strain accelerates dissolution, stabilizing intermediate states with broken bonds before full atom detachment, while the free energy profile of unstrained surfaces is almost monotonic. The atomistic calculations provided input for a kinetic model, predicting the shape evolution of a blunt crack tip, which displays three distinct regimes: (i) dissolution primarily away from the tip, (ii) enhanced blunting near but not at the apex, and (iii) sharpening near the apex. The transition between regimes occurs at a low strain, highlighting the critical role of water in the subcritical crack growth of oxide scales, with dissolution as the fundamental microscopic mechanism behind this process.

Chemistry↗
NASA NTRS1978

Friction and wear of polyethylene oxide polymer having a range of molecular weights

Sliding friction and wear experiments were conducted at light loads (25 to 250 g) with various molecular weights of the polyethylene oxide polymer sliding on itself and iron. Results of the experimental investigation indicate that: (1) the coefficient of friction for the polymer decreases with increasing molecular weight; (2) friction coefficient is higher for the polymer sliding on itself than it is for the polymer sliding on iron; (3) at sufficiently high loads localized surface melting occurs and the friction coefficient is the same for the polymer sliding on itself and iron; (4) fracture cracks develop in the sliding wear track at higher but not lower sliding velocities, reflecting a strain rate sensitivity to crack initiation, and (5) the friction coefficient for the polymer sliding on iron increases with the formation of a polymer film on the iron surface.

Buckley, D. H.↗
NASA NTRS2007

Three Dimensional Constraint Effects on the Estimated (Delta)CTOD during the Numerical Simulation of Different Fatigue Threshold Testing Techniques

Variation in constraint through the thickness of a specimen effects the cyclic crack-tip-opening displacement (DELTA CTOD). DELTA CTOD is a valuable measure of crack growth behavior, indicating closure development, constraint variations and load history effects. Fatigue loading with a continual load reduction was used to simulate the load history associated with fatigue crack growth threshold measurements. The constraint effect on the estimated DELTA CTOD is studied by carrying out three-dimensional elastic-plastic finite element simulations. The analysis involves numerical simulation of different standard fatigue threshold test schemes to determine how each test scheme affects DELTA CTOD. The American Society for Testing and Materials (ASTM) prescribes standard load reduction procedures for threshold testing using either the constant stress ratio (R) or constant maximum stress intensity (K(sub max)) methods. Different specimen types defined in the standard, namely the compact tension, C(T), and middle cracked tension, M(T), specimens were used in this simulation. The threshold simulations were conducted with different initial K(sub max) values to study its effect on estimated DELTA CTOD. During each simulation, the DELTA CTOD was estimated at every load increment during the load reduction procedure. Previous numerical simulation results indicate that the constant R load reduction method generates a plastic wake resulting in remote crack closure during unloading. Upon reloading, this remote contact location was observed to remain in contact well after the crack tip was fully open. The final region to open is located at the point at which the load reduction was initiated and at the free surface of the specimen. However, simulations carried out using the constant Kmax load reduction procedure did not indicate remote crack closure. Previous analysis results using various starting K(sub max) values and different load reduction rates have indicated DELTA CTOD is independent of specimen size. A study of the effect of specimen thickness and geometry on the measured DELTA CTOD for various load reduction procedures and its implication in the estimation of fatigue crack growth threshold values is discussed.

Seshadri, Banavara R.↗
DOE OSTI2024

The influence of electrode crack dimensions on the durability of polymer electrolyte membrane fuel cells

Electrode cracks in polymer electrolyte membrane fuel cells (PEMFCs) are correlated with early onset failures. Here, in this work we investigate the influence of cracked gas diffusion electrodes (GDEs) on the durability of the membrane electrode assembly (MEA) using a combined chemical-mechanical accelerated stress test (AST). Electrode crack dimensions were systematically tuned using ink formulations and material selection strategies. A parameter to describe the crack width areal density (Φ CW ) was used to quantify the degree of discontinuity in the electrode surfaces. Open circuit voltage (OCV) transient analyses were used to benchmark and characterize the failure mechanisms in the MEAs as a function of the Φ CW . While smaller electrode-level cracks, on the order of microns, yielded a 28 % decrease in operating lifetime, larger cracks that propagated from a discontinuous, microporous layer (MPL) coating, decreased the operating lifetime by 56 %. This work emphasizes the need for material processing strategies that consider defect tolerances to limit membrane failures in PEMFCs.

08 HYDROGEN↗
NASA NTRS1986

An assessment of the small-crack effect for 2024-T3 aluminum alloy

Data on small-crack behavior were obtained for a single-edge-notched tensile specimen made of 2024-T3 Al alloy and used to evaluate the capability of a semiempirical crack-growth and closure model to predict the fatigue life of notched specimens. Fatigue tests were conducted under either constant-amplitude loading (with stress ratios of 0.5, 0, -1, and -2) or spectrum loading, using a replication technique to record growth. It was found that small cracks exhibited the 'small-crack' effect in that they grew faster than large cracks when subjected to the same stress intensity factor range. Experimental small-crack growth rates agreed well with the model predictions. For making predictions of fatigue life, an initial surface defect void size of 3 x 12 x 0.4 microns was used in all calculations; predicted fatigue lives agreed well with experimentally determined values obtained in all tests. The crack-closure model indicated that the 'small-crack' effect on fatigue life was greatest in tests involving significant compressive loads.

Newman, J. C., Jr.↗
NASA NTRS2003

Leak Location and Classification in the Space Shuttle Main Engine Nozzle by Infrared Testing

The Space Shuttle Main Engine (SSME) is composed of cooling tubes brazed to the inside of a conical structural jacket. Because of the geometry there are regions that can't be inspected for leaks using the bubble solution and low-pressure method. The temperature change due escaping gas is detectable on the surface of the nozzle under the correct conditions. The methods and results presented in this summary address the thermographic identification of leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute temperature change associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Russell, Samuel S.↗
DOE OSTI2020

Long-Term Cyclability of NCM-811 at High Voltages in Lithium-Ion Batteries: an In-Depth Diagnostic Study

High-nickel layered oxides, such as LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM-811), offer higher energy density than their low-nickel counterparts at a given voltage and are gaining major traction in automotive lithium-ion batteries for electric vehicles. Besides high-Ni content, higher charging voltages above 4.3 V vs Li + /Li boost the energy and represent another focus in battery development. Here, we investigate the long-term cyclability of NCM-811 in graphite pouch cells over 1000 deep cycles between 2.5–4.2, 2.5–4.4, and 2.5–4.5 V through a suite of sensitive characterization techniques. The NCM-811 full cells show severely deteriorated cyclability with higher charging voltages, from 78% at 4.2 V to 52 and 32% at 4.4 and 4.5 V, respectively. At 4.2 V, minor parasitic electrolyte oxidation as well as cathode Li/Ni mixing and cracking are revealed after cycling, while transition-metal dissolution and surface reconstruction into rock-salt NiO are virtually undetectable. At 4.4 and 4.5 V, transition-metal dissolution and crossover to the anode become much more pronounced and a primary contributor to the capacity fade, while significant surface NiO formation causes substantial voltage polarization, which is less noticeable at 4.2 V. Meanwhile, more severe electrolyte oxidation, Li/Ni mixing, and particle pulverization exacerbate the voltage and capacity fade. Finally, these results outline distinct challenges for stable high-Ni layered oxide cathodes in high-voltage Li-ion batteries.

25 ENERGY STORAGE↗