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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6

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NASA NTRS1984

Constitutive modeling for isotropic materials

A state-of-the-art review of applicable constitutive models with selection of two for detailed comparison with a wide range of experimental tests was conducted. The experimental matrix contained uniaxial and biaxial tensile, creep, stress relaxation, and cyclic fatigue tests at temperatures to 1093 C and strain rates from .0000001 to .001/sec. Some nonisothermal cycles will also be run. The constitutive models will be incorporated into the MARC finite element structural analysis program with a demonstration computation made for advanced turbine blade configuration. In the code development work, particular emphasis is being placed on developing efficient integration algorithms for the highly nonlinear and stiff constitutive equations. Another area of emphasis is the appropriate and efficient methodology for determing constitutive constants from a minimum extent of experimental data.

Lindholm, U. S.↗

DOE OSTI2021

Accurate Effective Stress Measures: Predicting Creep Life for 3D Stresses Using 2D and 1D Creep Rupture Simulations and Data

Operating structural components experience complex loading conditions resulting in 3D stress states. Current design practice estimates multiaxial creep rupture life by mapping a general state of stress to a uniaxial creep rupture correlation using effective stress measures. The data supporting the development of effective stress measures are nearly always only uniaxial and biaxial, as 3D creep rupture tests are not widely available. This limitation means current effective stress measures must extrapolate from 2D to 3D stress states, potentially introducing extrapolation error. In this work, we use a physics-based, crystal plasticity finite element model to simulate uniaxial, biaxial, and triaxial creep rupture. Here, we use the virtual dataset to assess the accuracy of current and novel effective stress measures in extrapolating from 2D to 3D stresses and also explore how the predictive accuracy of the effective stress measures might change if experimental 3D rupture data was available. We confirm these conclusions, based on simulation data, against multiaxial creep rupture experimental data for several materials, drawn from the literature. The results of the virtual experiments show that calibrating effective stress measures using triaxial test data would significantly improve accuracy and that some effective stress measures are more accurate than others, particularly for highly triaxial stress states. Results obtained using experimental data confirm the numerical findings and suggest that a unified effective stress measure should include an explicit dependence on the first stress invariant, the maximum tensile principal stress, and the von Mises stress.

36 MATERIALS SCIENCE↗

DOE OSTI2022

BISON validation of FeCrAl cladding mechanical failure during simulated reactivity-initiated accident conditions*

Here, a reactivity-initiated accident (RIA) is a postulated design basis accident in light water reactors (LWRs) in which a rapid reactivity insertion induces a fission rate increase and a fuel pellet temperature rise. During RIA, the fuel pellet thermally expands and may cause pellet-cladding mechanical interaction (PCMI). Separate effects PCMI tests were performed on C26M FeCrAl cladding tube samples, introducing biaxial stress via a well understood modified burst test (MBT) system. A high-speed camera in the MBT system captured the projections, covering a 360° view of the cladding deformation and enabling a digital image correlation (DIC) method to quantify the surface strains with high fidelity. Representative hot zero-power RIA mechanical loading conditions were applied to the sample, and the test duration ranged from 20 to 500 ms at an average temperature of 573 K. BISON finite element–based fuel performance code modeling was performed against the high-fidelity DIC data produced from the MBTs. Validation calculations were conducted with 2D models and systematically compared with test data of the burst time, burst pressure, burst hoop strains, and hoop strain rates. Based on the behaviors from the separate effects test, BISON calculations satisfactorily predicted the cladding deformation behaviors. Sensitivity analysis was conducted to identify highly influential mechanical properties responsible for the cladding failure behavior during the MBT experiments. The results highlight the significance of the cladding's mechanical strength in governing cladding strain, followed by the significance of the mechanical interactions between the pellet and the cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1994

Assessment of impact damage of composite rocket motor cases

This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.

Paris, Henry G.↗

NASA NTRS1973

Establishment, test and evaluation of a prototype volcano surveillance system

A volcano-surveillance system utilizing 23 multilevel earthquake counters and 6 biaxial borehole tiltmeters is being installed and tested on 15 volcanoes in 4 States and 4 foreign countries. The purpose of this system is to give early warning when apparently dormant volcanoes are becoming active. The data are relayed through the ERTS-Data Collection System to Menlo Park for analysis. Installation was completed in 1972 on the volcanoes St. Augustine and Iliamna in Alaska, Kilauea in Hawaii, Baker, Rainier and St. Helens in Washington, Lassen in California, and at a site near Reykjavik, Iceland. Installation continues and should be completed in April 1973 on the volcanoes Santiaguito, Fuego, Agua and Pacaya in Guatemala, Izalco in El Salvador and San Cristobal, Telica and Cerro Negro in Nicaragua.

Ward, P. L.↗

NASA NTRS1975

Experimental study of transient liquid motion in orbiting spacecraft

The results are presented of a twofold study of transient liquid motion such as that which will be experienced during orbital maneuvers by space tug. A test program was conducted in a low-g test facility involving twenty-two drops. Biaxial, low-g accelerations were applied to an instrumented, model propellant tank during free-fall testing, and forces exerted during liquid reorientation were measured and recorded. Photographic records of the liquid reorientation were also made. The test data were used to verify a mechanical analog which portrays the liquid as a point mass moving on an ellipsoidal constraint surface. The mechanical analog was coded into a FORTRAN IV digital computer program: LAMPS, Large AMPlitude Slosh. Test/analytical correlation indicates that the mechanical analog is capable of predicting the overall force trends measured during testing.

Berry, R. L.↗

DOE OSTI2016

Effect of hydrogen on irradiation creep and growth for ZIRLO alloy and Zr-1.0Nb - 2016-0058

The impact of hydrogen on the irradiation growth and creep of stress-relief annealed (SRA) ZIRLO{sup R} alloy and recrystallized annealed (RXA) Zr-1.0Nb cladding tubes is evaluated in this paper. The samples were charged with hydrogen in the range of approximately 160-720 ppm using the gaseous method. Biaxial in-reactor creep tests were performed after Cycle 1, Cycle 2, Cycle 3, and Cycle 4, on both as received and pre-charged hydrogen cladding tubes. Outside diameter and axial length measurements were performed on the samples. The results showed that hydrogen had no effect on the axial irradiation creep but a relatively large effect on the axial irradiation growth. Increasing hydrogen decreased the axial irradiation growth in RXA Zr-1.0 Nb, which was opposite from the behavior of SRA ZIRLO cladding. This unique hydrogen effect on the irradiation axial growth of RXA Zr-1.0Nb could be due to the different intergranular stress resulting from the fabrication process or the absence of alloying elements, including tin. The total axial strain of both Zr-1.0Nb and SRA ZIRLO cladding increased with increasing fast fluence, and Zr-1.0Nb increased at a faster rate relative to SRA ZIRLO cladding. In the diameter direction, hydrogen had a minimal effect on the total diameter strain and the diameter irradiation creep strain for both SRA ZIRLO samples and the RXA Zr-1.0Nb sample. This finding from in-reactor test is contrary to the out-reactor tests results from the literature that have shown that hydrogen significantly decreases thermal creep. The total diameter strain and diameter irradiation creep behavior for the SRA ZIRLO samples and RXA Zr-1.0Nb were similar. (authors)

36 MATERIALS SCIENCE↗

NASA NTRS1990

Compressive failure of thick-section composite laminates with and without cutouts subjected to biaxial loading

The composites studied are fiber composite laminate plates made of carbon fibers and a thermoplastic matrix material. Tests and results are given for: the solution convergence for transverse shear in a clamped plate without cutout under compression; the effects of cutout and laminate thickness on maximum shear in buckling and postbuckling response of a clamped plate under biaxial compression; the effects of cutout and laminate thickness on maximum shear in buckling and postbuckling response of a clamped plate under biaxial compression; and the effects of laminate thickness and cutout of the lowest three eigenvalues of a clamped plate under biaxial compression. Additional test results are given.

Rouxel, L.↗

NASA NTRS2002

Generalized Reliability Methodology Applied to Brittle Anisotropic Single Crystals

A generalized reliability model was developed for use in the design of structural components made from brittle, homogeneous anisotropic materials such as single crystals. The model is based on the Weibull distribution and incorporates a variable strength distribution and any equivalent stress failure criteria. In addition to the reliability model, an energy based failure criterion for elastically anisotropic materials was formulated. The model is different from typical Weibull-based models in that it accounts for strength anisotropy arising from fracture toughness anisotropy and thereby allows for strength and reliability predictions of brittle, anisotropic single crystals subjected to multiaxial stresses. The model is also applicable to elastically isotropic materials exhibiting strength anisotropy due to an anisotropic distribution of flaws. In order to develop and experimentally verify the model, the uniaxial and biaxial strengths of a single crystal nickel aluminide were measured. The uniaxial strengths of the <100> and <110> crystal directions were measured in three and four-point flexure. The biaxial strength was measured by subjecting <100> plates to a uniform pressure in a test apparatus that was developed and experimentally verified. The biaxial strengths of the single crystal plates were estimated by extending and verifying the displacement solution for a circular, anisotropic plate to the case of a variable radius and thickness. The best correlation between the experimental strength data and the model predictions occurred when an anisotropic stress analysis was combined with the normal stress criterion and the strength parameters associated with the <110> crystal direction.

Salem, Jonathan A.↗

NASA NTRS1977

Method for measuring biaxial stress in a body subjected to stress inducing loads

A method is described for measuring stress in test articles including the steps of obtaining for a calibrating specimen a series of transit time differentials between the second wave echo for a longitudinal wave and the first wave echo for each of a pair of shear waves propagated through the specimen as it is subjected to known stress load of a series of stress loads for thus establishing a series of indications of the magnitudes for stress loads induced in the specimen, and thereafter obtaining a transit time differential between the second wave echo for a longitudinal wave and the first wave echo for each of a pair of shear waves propagated in the planes of the stress axes of a test article and comparing the transit time differential thus obtained to the series of transit time differentials obtained for the specimen to determine the magnitude of biaxial stress in the test article.

Clotfelter, W. N.↗

NASA NTRS1989

Application of cyclic damage accumulation life prediction model to high temperature components

A high temperature, low cycle fatigue life prediction method was developed. This method, Cyclic Damage Accumulation (CDA), was developed for use in predicting the crack initiation lifetime of gas turbine engine materials, but it can be applied to other materials as well. The method is designed to account for the effects on creep-fatigue life of complex loading such as thermomechanical fatigue, hold periods, waveshapes, mean stresses, multiaxiality, cumulative damage, coatings, and environmental attack. Several features of this model were developed to make it practical for application to actual component analysis, such as the ability to handle nonisothermal loading (including TMF), arbitrary cycle paths, and multiple damage modes. The CDA life prediction model was derived from extensive specimen tests conducted on cast nickel-base superalloy B1900 + Hf. These included both monotonic tests (tensile and creep) and strain-controlled fatigue experiments (uniaxial, biaxial, TMF, mixed creep-fatigue, and controlled mean stress). Additional specimen tests were conducted on wrought INCO 718 to verify the applicability of the final CDA model to other high-temperature alloys. The model will be available to potential users in the near future in the form of a FORTRAN-77 computer program.

Nelson, Richard S.↗

NASA NTRS2000

Strain Measurement System Developed for Biaxially Loaded Cruciform Specimens

A new extensometer system developed at the NASA Glenn Research Center at Lewis Field measures test area strains along two orthogonal axes in flat cruciform specimens. This system incorporates standard axial contact extensometers to provide a cost-effective high-precision instrument. The device was validated for use by extensive testing of a stainless steel specimen, with specimen temperatures ranging from room temperature to 1100 F. In-plane loading conditions included several static biaxial load ratios, plus cyclic loadings of various waveform shapes, frequencies, magnitudes, and durations. The extensometer system measurements were compared with strain gauge data at room temperature and with calculated strain values for elevated-temperature measurements. All testing was performed in house in Glenn's Benchmark Test Facility in-plane biaxial load frame.

Krause, David L.↗

NASA NTRS1983

Failure analysis of composite laminates including biaxial compression

This report describes a continued effort on the development and application of the tensor polynomial failure criterion for composite laminate analysis. In particular, emphasis is given to the design, construction and testing of a cross-beam laminate configuration to obtain "pure' biaxial compression failure. The purpose of this test case was to provide to permit "closure' of the cubic form of the failure surface in the 1-2 compression-compression quadrant. This resulted in a revised set of interaction strength parameters and the construction of a failure surface which can be used with confidence for strength predictions, assuming a plane stress state exists. Furthermore, the problem of complex conjugate roots which can occur in some failure regions is addressed and an "engineering' interpretation is provided. Results are presented illustrating this behavior and the methodology for overcoming this problem is discussed.

Tennyson, R. C.↗

DOE OSTI2017

Strain distribution and failure mode of polymer separators for Li-ion batteries under biaxial loading

Deformation of polymer separators for Li-ion batteries has been studied under biaxial tension by using a dome test setup. This deformation mode provides characterization of separator strength under more complex loading conditions, closer representing deformation of an electric vehicle battery during crash event, compared to uniaxial tension or compression. Two polymer separators, Celgard 2325 and Celgard 2075 were investigated by deformation with spheres of three different diameters. Strains in separators were measured in situ by using Digital Image Correlation (DIC) technique. The results show consistent rupture of separators along the machine direction coinciding with areas of high strain accumulation. The critical first principal strain for failure was independent of the sphere diameter and was determined to be approximately 34% and 43% for Celgard 2325 and Celgard 2075 respectively. These values can be taken as a criterion for internal short circuit in a battery following an out-of-plane impact. A Finite Element (FE) model was built with the anisotropic description of separator behavior, derived from tensile tests in orthogonal directions. In conclusion, the results of simulations predicted the response of separator rather well when compared to experimental results for various sizes of rigid sphere.

25 ENERGY STORAGE↗

DOE OSTI2020

Sapphire advanced mitigation process: wet etch to expose sub-surface damage and increase laser damage resistance and mechanical strength

In this study, a novel, to the best of our knowledge, method of wet chemical etching of sapphire workpieces (such as optics, wafers, windows, and cones), called the sapphire advanced mitigation process (or sapphire AMP), has been developed that exposes sub-surface mechanical damage created during the optical fabrication process and significantly enhances the surface laser damage resistance (> 2×) and mechanical strength (up to ~ 2.6×). Sapphire AMP involves first treating the workpiece with a mixture of sulfuric and phosphoric acid ([H 2 SO 4 ]:[H 3 PO 4 ]= 1 : 3) at 220°C, followed with phosphoric acid at 160°C, then with sodium hydroxide base (NaOH) and surfactant at 40°C, and finally with a high-pressure deionized water spray rinse. Sapphire AMP has been demonstrated on both A- and C-plane sapphire workpieces. The mechanism of this etch process involves the reaction of the sapphire (Al 2 O 3 ) surface with sulfuric acid (H 2 SO 4 ) forming aluminum sulfate [Al2(SO4)3], which has low solubility. The high phosphoric acid content in the first and second steps of sapphire AMP results in the efficient conversion of Al 2 (SO 4 ) 3 to aluminum phosphate (AlPO 4 ), which is very soluble, greatly reducing reaction product redeposition on the workpiece surface. Sapphire AMP is shown to expose sub-surface mechanical damage on the sapphire surface created during the grinding and polishing processes, whose etched morphology has either isotropic or anisotropic evolution depending on the nature of the initial surface damage. Sapphire AMP was also designed to remove the key known surface, laser absorbing precursors (namely, foreign chemical impurities, the fracture surface layer of preexisting sub-surface damage, and reaction product or foreign species redeposition or precipitation). Static and sliding indention induced surface microfractures on sapphire are shown after sapphire AMP to have a significant decrease in the fast photoluminescence intensity (a known metric for measuring the degree of laser damaging absorbing precursors). In addition, the onset of laser damage (at 351 nm 3 ns) on sapphire AMP treated workpieces was shown to increase in fluence from ~ 4 to >9.5J/cm 2 . Finally, biaxial ball-on-ring mechanical tests on sapphire disks showed an increase in the failure stress from 340 MPa (with pre-existing 28 µm flaws) to ~ 900MPa after sapphire AMP, which is attributed to the blunting of the surface microfractures.

36 MATERIALS SCIENCE↗

NASA NTRS1976

Miniature biaxial strain transducer

A reusable miniature strain transducer for use in the measurement of static or quasi-static, high level, biaxial strain on the surface of test specimens or structures was studied. Two cantilever arms, constructed by machining the material to appropriate flexibility, are self-aligning and constitute the transducing elements of the device. Used in conjunction with strain gages, the device enables testing beyond normal gage limits for high strains and number of load cycles. The device does not require conversion computations since the electrical output of the strain gages is directly proportional to the strain measured.

Hoffman, I. S.↗

NASA NTRSDate not supplied

Bi-axial Strain Measurement of Woven-Webbing Inflatable Structures Using Digital Image Correlation with RGB Filtering

Crewed inflatable softgoods structures can significantly reduce launch volume for habitable pressure vessels. To ensure the operational safety of these structures, NASA has developed an extensive testing program to evaluate the structural capability on ground test articles. This paper will discuss a current challenge faced by test engineers evaluating the strain of large-scale inflatable space structures during ground testing. Namely, the difficulty that arises using monochrome digital image correlation (DIC) to evaluate bi-axial strain for woven-webbing restraint layers. This report provides insight into a novel method of photogrammetry using red-green-blue (RGB) filtering in conjunction with DIC to evaluate the strain in each direction on a test article experiencing bi-directional strain. To evaluate this concept, a uniaxial tensile test was performed that represented a biaxial woven architecture using orthogonally interfaced straps. The resulting analysis demonstrates promise for this novel approach for isolating a specific region and direction of strain, reducing the effects of straps not in the area of interest, while allowing for a larger region of analysis. Moreover, it was shown that the application of a white basecoat prior to applying photogrammetry patterns significantly reduced data loss while performing RGB filtered DIC.

inflatable↗

DOE OSTI2014

Magnetic and electric bulge-test instrument for the determination of coupling mechanical properties of functional free-standing films and flexible electronics

For the first time a novel multi-field bulge-test instrument which enables measurements of the biaxial mechanical properties and electro-magnetic-mechanical coupling effect of free-standing films in external magnetic/electric fields was proposed. The oil pressure was designed with two ranges, 0–1 MPa for elastic small deformation and 0–7 MPa for plastic/damage large deformation. A magnetic field that was horizontal and uniform in the film plane was supplied by a hollow cylindrical magnet. The magnitude could be changed from 0 to 10 000 Oe by adjusting the position of the testing film. Meanwhile, an electric field applied on the film was provided by a voltage source (Maximum voltage: 1000 V; Maximum current: 1 A). Various signals related to deformation, mechanical loading, magnetic field, and electric field could be measured simultaneously without mutual interference, which was confirmed by the coincidence of the measured P-H curves for titanium (Ti)/nickel (Ni) specimens with/without external fields. A hardening phenomenon under magnetic/electric fields was observed for Ni and lead zirconate titanate specimens. The multi-field bulge-test instrument will provide a powerful research tool to study the deformation mechanism of functional films and flexible electronics in the coupling field.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗