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Results for “brittle fracture”

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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Laser Additive Manufacturing Process Development for Bismuth Telluride Thermoelectric Material

Thermoelectric generators have strong potential for aerospace and aircraft applications. However, traditional manufacturing methods for thermoelectric devices severely limit device adaptability and consequently marketability. Laser powder bed fusion is an additive manufacturing method which shows promising potential for producing thermoelectric devices. Thermoelectric materials pose unique challenges compared to metals because of low thermal conductivity, brittle fracture characteristics, and irregular powder particle morphologies. Herein, we communicate processing procedures to fabricate thermoelectric parts of Bi 2 Te 3 through laser powder bed fusion. In this study, we identify the successful combination of key process parameters—laser power, scan speed, hatch distance, and powder layer thickness—to achieve high-quality parts in terms of density and physical properties, and we demonstrate the impact of process parameter variation on built part quality. While it cannot exclusively determine part quality, the volumetric energy density is a useful guide in deciding process parameters for thermoelectric materials, and the optimal value is between 9 and 11 J/mm 3 for Bi 2 Te 3 . We demonstrate successful fabrication of different freeform geometries of Bi 2 Te 3 powders. The results suggest it is possible to extend this method more broadly to other semiconductor materials, including thermoelectric power generation materials applicable for space applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dynamic Tensile Response of a Fe–49Co–2V Alloy at Various Strain Rates and Temperatures

Soft ferromagnetic alloys are often utilized in electromagnetic applications due to their desirable magnetic properties. In support of these applications, the ferromagnetic alloys are also required to bear mechanical load under various loading and environmental conditions. In this study, a Fe–49Co–2V alloy was dynamically characterized in tension with a Kolsky tension bar and a Drop–Hopkinson bar at various strain rates and temperatures. Dynamic tensile stress–strain curves of the Fe–49Co–2V alloy were obtained at strain rates ranging from 40 to 230 s -1 and temperatures from - 100 to 100 °C. All dynamic tensile stress–strain curves exhibited an initial linear elastic response to an upper yield followed by Lüders band response and then a nearly linear work-hardening behavior. The yield strength of this material was found to be sensitive to both strain rate and temperature, whereas the hardening rate was independent of strain rate or temperature. The Fe–49Co–2V alloy exhibited a feature of brittle fracture in tension under dynamic loading with no necking being observed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Facile healing of cracks in organic–inorganic halide perovskite thin films

Organic-inorganic halide perovskite (OIHP) thin films at the heart of the burgeoning thin-film perovskite solar cells (PSCs) technology possess poor mechanical properties, which is likely to limit the long-term reliability of PSCs as they are poised for commercialization. In an effort to address this issue, in this work we demonstrate that through-thickness cracks induced by bending-tension in thin films of the two prototypical OlHPs, methylammonium lead triiodide (MAPbl(3)) and formamidinium lead triiodide (FAPbl(3)), can be healed easily. This is through the application of either a moderate compressive stress (bending-compression) at room temperature or a simple heat-treatment at modest temperatures. The crack-healing process is found to be time-dependent, which indicates that facile mass-transport in OlHPs plays a key role in this phenomenon. An explanation for this phenomenon is provided, one based on the fundamentals of brittle fracture. This discovery has broad implications for the prevention and/or restoration of the overall performance, environmental stability, and mechanical reliability of PSCs, and other devices.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Additive manufacturing of continuous carbon fiber-reinforced SiC ceramic composite with multiple fiber bundles by an extrusion-based technique

Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber-reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water-based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is conjectured to be due to the reaction between SiO and carbon fiber at high temperature. The continuous carbon fiber-reinforced SiC ceramic composite exhibited non-brittle fracture. In conclusion, the flexural strength of the additively manufactured Cf/SiC composites improved from 162 MPa with no fiber bundles to a maximum of 219 MPa with three fiber bundles.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A hybrid meshfree discretization to improve the numerical performance of peridynamic models

Efficient and accurate calculation of spatial integrals is of major interest in the numerical implementation of peridynamics (PD). The standard way to perform this calculation is a particle-based approach that discretizes the strong form of the PD governing equation. This approach has rapidly been adopted by the PD community since it offers some advantages. Additionally, it is computationally cheaper than other available schemes, can conveniently handle material separation, and effectively deals with nonlinear PD models. Nevertheless, PD models are still computationally very expensive compared with those based on the classical continuum mechanics theory, particularly for large-scale problems in three dimensions. This results from the nonlocal nature of the PD theory which leads to interactions of each node of a discretized body with multiple surrounding nodes. Here, we propose a new approach to significantly boost the numerical efficiency of PD models. We propose a discretization scheme that employs a simple collocation procedure and is truly meshfree; i.e., it does not depend on any background integration cells. In contrast to the standard scheme, the proposed scheme requires a much smaller set of neighboring nodes (keeping the same physical length scale) to achieve a specific accuracy and is thus computationally more efficient. Our new scheme is applicable to the case of linear PD models and within neighborhoods where the solution can be approximated by smooth basis functions. Therefore, to fully exploit the advantages of both the standard and the proposed schemes, a hybrid discretization is presented that combines both approaches within an adaptive framework. The high performance of the developed framework is illustrated by several numerical examples, including brittle fracture and corrosion problems in two and three dimensions.

42 ENGINEERING↗
DOE OSTI2021

Effect of strain rate on the deformation of hollow CoS nanoboxes and doubly porous self-assembled films

Nanomaterials with multiscale porosity are attractive as lightweight structural materials because unique deformation mechanisms can be programmed at different length scales. Here, we explore this concept by investigating the mechanics of hollow nanoboxes, as well as films self-assembled from nanoboxes. Hollow CoS nanoboxes with lengths of 900 nm and <30 nm wall thickness are synthesized using colloidal methods. Individual nanoboxes are compressed inside a scanning electron microscope at strain rates of 0.001 s –1 , 0.01 s –1 , and 0.1 s –1 . Nanoboxes are found to have a first peak stress of 15 MPa and loading modulus of ~240 MPa regardless of strain rate. The nanoboxes deform through ductile, plastic bending of side walls at 0.001 s –1 strain rate, while brittle fracture occurs at the higher strain rates. Self-assembly of these nanoboxes results in films with relative density of <0.1. Nanoindentation shows strain rate independent behavior with average modulus and hardness of ~15 MPa and ~230 kPa, respectively. Furthermore, the mechanical behavior of the film is compared to that of the nanobox building blocks, cellular foams and granular materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Atomic force microscopy monitoring of subcritical slow crack growth in soda lime silicate glass

Prediction of brittle fracture in silicate glasses requires a fundamental understanding of slow crack growth rates, far below the critical stress intensity (K IC ) of the material. Here, in this study, atomic force microscopy (AFM) was used to characterize slow crack propagation in soda lime silicate glasses. Using large-sample AFM systems with specialized tips and scanners, fractures less than 20 nm wide were measured as a function of relative humidity (RH). The results were found to be sensitive to the type of AFM tip used and to the dryness of the surface. Continuous scanning and image capture over several days allowed the determination of the crack tip velocity. The dependance of crack tip velocity on RH was measured by enclosing the sample and AFM head in a humidity-controlled chamber. The crack tip velocity was measured as low 4.0×10 -12 m/s at 15 % RH and as high as 3.7×10 -10 m/s at 40 % RH. Overall crack growth was smooth during the AFM scan. Additionally, recession of the crack tip was noted as the sample dried, indicating crack tip closure may be occurring. Further studies on alternative compositions will provide details on subcritical fracture processes in a range of different environmental conditions.

Atomic force microscopy↗
DOE OSTI2022

Friction-based riveting technique for AZ31 magnesium alloy

Rivet materials used in the aerospace and automotive industries are typically alloys of aluminum (Al) or steel. Magnesium (Mg) is an attractive alternative because it is 33% and 75% lighter than Al and steel, respectively. However, a primary barrier for using Mg as rivet material is its poor formability at room temperature, resulting in brittle fracture of the rivet head during cold riveting. Hot riveting is possible but suffers from high cycle time due to the need for pre-heating. A new friction-based riveting technique, Rotating Hammer Riveting (RHR), is reported to fully form AZ31 Mg rivet heads in a mere 0.23 seconds cycle time. Heat and pressure generated through severe plastic deformation during the process was sufficient to form the Mg rivet head without the need for a separate pre-heating operation. Due to dynamic recrystallization, AZ31 Mg grains in the rivet head were significantly refined from about 15 to 2.6 µm during RHR, which favors the formability of Mg rivet by triggering grain boundary sliding and reducing plastic anisotropy of Mg. In addition, RHR joints showed a metallurgical bond between the rivet head and top sheet, which eliminates a significant pathway for corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High temperature tensile properties of H13 tool steel fabricated via binder jet additive manufacturing

H13 is one of the most used steels for hot work tooling applications like die casting. Binder jet additive manufacturing (BJAM) offers a cost-effective solution to fabricate tools with performance enhancing features like internal cooling channels. While full densification of BJAM H13 has been demonstrated in the literature, the room and high temperature tensile properties of the material, and the effect of post-process treatments like hot isostatic pressing (HIP), and heat treatment (HT) are unknown. Here we use HIP+HT to obtain a combination of ultimate tensile strength (UTS) and elongation to failure that is superior to H13 fabricated via laser powder bed fusion and wire arc additive manufacturing. HIP+HT BJAM H13 has a superior UTS (1836 MPa) compared with conventionally processed (1671 MPa) H13 but has lower plastic elongation. We report that as-sintered samples have an extensive network of continuous grain boundary (GB) carbides that contribute to brittle fracture. HIP+HT results in partial dissolution of GB carbides and formation of a fine martensitic microstructure resulting in superior tensile strength and elongation compared with as-sintered H13. We use thermo-kinetic calculations to rationalize the effects of HIP+HT on microstructure and properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Tensile properties of powder-metallurgical-processed tungsten alloys after neutron irradiation near recrystallization temperatures

The tensile properties of powder-metallurgical-processed Pure W, K-doped W, W-3%Re, and K-doped W-3%Re were examined after neutron irradiation up to 0.7 dpa at 910–1020 °C with a thermal neutron shield in the High Flux Isotope Reactor (HFIR). After irradiation, recrystallized Pure W (R) exhibited a brittle fracture mode, while recrystallized K-doped W-3%Re (R) exhibited a ductile fracture mode at 500 °C. K-doped W-3%Re (R) has fine grains, and hence, contains a considerable number of grain boundaries that act as sinks for irradiation defects. Solid solute Re in the W matrix could improve not only the mechanical properties of W, but also its resistance to neutron irradiation. At 500 °C, the ductility of K-doped W-3%Re after irradiation was significantly higher than that of Pure W. The irradiation at ~1000 °C did not induce hardening of stress-relieved (SR) W materials, but SR W materials tended to exhibit a decrease in the ultimate tensile strength (UTS) and an increase in total elongation (TE). Here, the softening due to the recovery and recrystallization of SR W materials and the hardening due to the formation of irradiation defect clusters were balanced during irradiation at ~1000 °C, and ductility was exhibited without an increase in strength.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Small-scale mechanical testing and characterization of fuel cladding chemical interaction between HT9 cladding and advanced U-based metallic fuel alloy

Fuel cladding chemical interactions (FCCI) occurred on the interface between the nuclear metal fuel and cladding is the primary cause of cladding wastage, weakening cladding mechanical integrity, and placing fuel and cladding at risk. Although the microstructural and phase information of FCCI has been fairly understood, mechanical properties remain less studied due to limited reaction volume. Here, through a combining of advanced electron microscopy characterizations and small-scale mechanical testing techniques, including indentation and micro-tensile testing, this study investigated the microscale mechanical properties of FCCI between the ferritic/martensitic (F/M) HT9 cladding and an advanced Uranium (U)-based metallic fuel irradiated at the Advanced Test Reactor to 2.2% FIMA with peak inner cladding temperature reached to 650 °C. Mechanical testing results show significant hardening and embrittlement in the FCCI region. The brittle fracture of FCCI specimen is mainly attributed to the formation of nano-crystallized intermetallic σ-FeCr phase. Whereas mechanical softening was revealed in the unreacted HT9 matrix due to irradiation-induced microstructural and microchemical evolution, specifically, the disappearance of martensitic lath structure and the formation of Fe 2 Mo Laves phase precipitation which consumed the solid solution strengthening Mo from the F/M HT9 matrix. Due to the achieved high cladding temperature, this fuel pin is of particular significance for revealing the high-temperature irradiation effect on the mechanical properties of HT9 cladding. Therefore, the outcomes of this study are expected to contribute to the development of multi-scale mechanical behavior modeling of HT9 cladding for Generation IV reactors which requires cladding to run at higher temperature (above 600 ?).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Evaluation of corrosion coupons exposed to molten-chloride electrorefiner salts long term

Corrosion mitigation has long been considered a challenge in long-term service of both pyrochemical reprocessing and molten salt reactor applications. Corrosion coupons consisting of 2.25Cr 1Mo ASME SA387 Grade 22 Class 2 steel, were installed in a uranium electrorefiner containing molten chloride salt at 500°C. This electrorefiner went into service at Idaho National Laboratory in 1994. Seven of these coupons were removed in 2019 (i.e., submerged in molten salt for 25 years) for analysis and characterization including neutron imaging, optical microscopy, scanning electron microscopy, and wave/energy dispersive x-ray spectroscopy. The results showed that all seven coupons experienced between 30 to 175 µm of surface degradation without evidence of brittle fracture. Meaning there was no evidence of accelerated corrosion or fractures, and the average steel surface loss was of less than 5 µm per year. All indications were that the environmental conditions inside the electrorefiner were favorable for the steel alloy.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Effect of copper content on the tensile elongation of Al–Cu–Mn–Zr alloys: Experiments and finite element simulations

Microstructures of cast aluminum alloys used in automotive engine applications often consist of intermetallic particles that can impact the tensile elongation of these alloys. Here in this paper, we investigate the effect of intermetallic grain boundary particles on tensile elongation by fabricating a series of alloys with Cu content varying between 6.0 - 9.0 wt% in cast Al–Cu–Mn–Zr (ACMZ) type compositions. The tensile elongation of as-aged ACMZ alloys decreases monotonically with increase in Cu content. While the microstructure within the grains and yield stress of the alloy remains invariant with Cu content, the decrease in tensile elongation correlates well with increase in the size and volume fraction of grain boundary particles. Microstructural observations are combined with finite element simulations to explain the trend in tensile elongation with changing Cu content. Crack initiation is found to occur by brittle fracture of the grain boundary particles. Increase in particle size promotes crack initiation by reduction in size dependent particle fracture strength. Lower inter-particle spacing at higher particle volume fraction further facilitates crack initiation by increasing stress within the particles caused by the interaction between stress fields of neighboring particles. Increase in particle volume fraction also accelerates crack propagation through the formation of macro shear zones in the microstructure. The increase in Cu content of cast ACMZ alloys, therefore, decreases tensile elongation by promoting both crack initiation and crack propagation.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructure and mechanical properties of high Mn-containing ferritic-martensitic alloys exposed to cyclical thermal treatment

Substantial residual tensile stress tends to accumulate in currently available high-Cr ferritic martensitic steels that are subjected to cyclical heat treatment, which leads to premature brittle fracture. By tailoring the alloy composition, this thermal cycling can be exploited to induce a high number density of nanoprecipitates and phase transformations countering residual tensile stresses. In this work, three new variants of ferritic-martensitic steels have been designed with computational thermodynamics to meet the goals of mitigating residual tensile stresses by lowering martensite start temperatures and of enhancing mechanical strength and irradiation sink strength by increasing the number density of nanoprecipitates. Furthermore, ctenast materials were subjected to cyclical heat treatment. The thermally cycled samples were evaluated with mechanical testing and microstructural analysis to identify the optimal composition in which figures of merit include low residual stress and a high density of nanoscale MX (M = metal, X = C/N) precipitates, leading to high yield strength with reasonable ductility. The noticeably higher density of nanoprecipitates in the optimal alloy favor its higher yield strength, which is supported by the microstructure-derived yield strength calculation and precipitation kinetics simulation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sensitivity analysis applied to SiC failure probability in TRISO modeled with BISON

Here, a sensitivity analysis on the failure probability of the Silicon Carbide (SiC) layer in tristructural isotropic (TRISO) nuclear fuel during transient conditions predicted by the BISON fuel performance code is performed. The principal goal of the analysis is to understand the most important parameters dictating SiC failure behavior in BISON during Reactivity Initiated Accidents (RIAs). SiC brittle fracture probability is modeled using Weibull statistics. A total of seven inputs related to SiC failure has been selected for the analysis, including the Weibull statistics parameters, elastic moduli for SiC and Pyrolitic Carbon (PyC) and SiC stress-free temperature. A 1D TRISO BISON model has been established for various reactivity insertions performed at the Nuclear Safety Research Reactor (NSRR). The principal advantage associated with the 1D TRISO model developed in this work is its computational efficiency. The Sobol variance decomposition method is used, and the sensitivity indices are presented for eight different values of the energy deposition. The results show that the two most important parameters impacting the predicted SiC failure probability are the Weibull modulus and the characteristic stress, and a co-variance amongst these parameters is obtained for low reactivity insertions. An additional new finding of this work is that the relative importance of Weibull parameters depends on the energy deposition, and thus reactivity, regime. For low energy depositions, two parameters are of influence on SiC failure probability, while for high energy depositions only one parameter impacts failure probability results. Moreover, optimization of the Weibull modulus and characteristic stress is performed by minimizing the RMSE between BISON failure probability predictions and experimental failure fractions for each energy deposition. This work also demonstrates the validity of the NSRR tests BISON simulations and of the respective sensitivity analysis results as conservative, yet indicative for slower transients characterized by lower deposited energies. Such verification is achieved through the partial extension of the analysis to a group Control Rod Withdrawal reproduced from a previous study. Another novel result of this analysis is that no single set of Weibull parameters can reproduce all reactivity insertion experimental failure results, which is related to the intrinsic nature of SiC failure properties, and a new range for the parameters is proposed to produce a failure probability envelope that encompasses the experimental fractions. Additionaly, this work proposes a new approach for future failure analysis with BISON, consisting in the use of Weibull parameters ranges, rather than fixed sets, along with failure envelopes generation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Water Weakening of Calcium Oxide

Chemomechanical processes such as water weakening can control the permeability and deformation of rocks and manmade materials. Here, atomistic modeling and nanomechanical experiments were used to identify molecular origins of chemomechanical effects in calcium oxide (CaO) and its effect on observed elastic, plastic, and brittle deformation. Classical molecular dynamics simulations with the bond order-based reactive force-field ReaxFF were used to assess brittle fracture. In the presence of water, CaO fractured earlier and more often during quasi-static loading, with a calculated reduction in fracture toughness of ~80% associated with changes in the stress distribution around the crack tip. Experimentally, elastic and plastic deformation of CaO surfaces exposed to water was assessed experimentally using in situ liquid nanoindentation. Nanoindentation showed that following exposure to water, the contact hardness decreased by 1–2 orders of magnitude and decreased the modulus by 2–3 orders of magnitude due to surface hydroxylation. Furthermore, the strong chemomechanical effects on the mechanical processes in CaO suggests that minerals with similar structures may exhibit comparable effects, influencing the stability of cements and geomaterials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Validated Reactive Force Field Quantifies MXene Interfacial Properties, Mechanics, and Thermal Transport

MXenes combine rich surface chemistry, mechanical strength, and high conductivity for a multitude of emerging applications. Predictive modeling supports accelerated materials designs and has been limited by the absence of validated and transferable force fields. Here, we introduce an interpretable, reactive INTERFACE force field (IFF and IFF-R) for Ti 3 C 2 T x MXenes that is trained based on chemical knowledge and achieves quantitative agreement with experiments across lattice parameters (<0.5%), density (<0.2%), liquid contact angles, Raman spectra, and the in-plane elastic modulus (∼320 GPa). The models cover surface terminations from hydroxyl (−OH) to fluorine (−F) groups and are extensible to other chemistries. We introduce pH-resolved surface chemistry and identify dopamine adsorption mechanisms at MXene–aqueous interfaces supported by QCM-D and UV–Vis experiments. The data reveal coplanar and perpendicular binding modes and concentration-dependent multilayer assembly. We predict previously inaccessible properties, including termination-dependent cleavage energies, interlayer shear moduli and dynamic shear failure, nanoindentation and brittle fracture, anisotropic in-plane and out-of-plane thermal conductivities, including the role of defects. Agreement with available experimental data is consistently close and exceeds DFT accuracy across the benchmark properties examined. The IFF/IFF-R model is compatible with CHARMM, AMBER, OPLS, and CVFF force fields for simulations of MXenes with diverse surface terminations, electrolyte interfaces, biointerfaces, and polymer composites without additional parameters. Parameter sets, 3D models, and analysis scripts are provided for community use. The validated, reactive, and transferable IFF framework facilitates predictive design of MXene-based films, membranes, sensing interfaces, and composites.

MXene↗
DOE OSTI2023

Performance of hybrid Innegra-carbon fiber composites

Abstract In this work material synergy with high stiffness carbon fiber with ductile high strength polypropylene fiber (Innegra S), (referred to as Innegra, herein) have been evaluated in a range of laminate designs. Both woven and discontinuous carbon fiber have been considered. The discontinuous fibers are based on three-dimensional deposition (3DEP) (referred to as 3DEP, herein) carbon fiber preform process. Eleven (11) variants of Innegra-carbon fiber hybrid laminates were investigated for tensile, flexure, compression, in-plane shear and low velocity impact response. The effect of position of Innegra within the laminate was studied and found to influence strength and stiffness properties. In terms of overall trends, Innegra provides upward of 18% improvement in strain (ductility) to the composite and eliminates brittle fracture of carbon fiber. The moduli trends follow the proportionality of Innegra fiber to carbon fiber plies. However, the strength is controlled by the interface between Innegra and carbon fiber. The primary failure mode in tension and compression is via onset of debonding between Innegra and carbon fiber. The 3DEP carbon fiber constituents provided highest values of in-plane shear indicating that three-dimensional (3D) network of carbon fiber provides higher shear resistance. The Innegra intensive variants exhibited superior energy absorption under low velocity impact, at energy levels 15–60 J. This work provides insight for designers to incorporate Innegra and carbon fiber hybrids in composite structures.

36 MATERIALS SCIENCE↗