SEARCH · Engineering Papers

Results for “time to failure”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,135 records · Page 63

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Annual and sub-seasonal dynamics of a rapidly eroding permafrost coastline along the Beaufort Sea in northern Alaska

Drew Point, an unlithified ice-rich permafrost coastline along the Alaskan Beaufort Sea, is among the most rapidly eroding Arctic coastlines, with an average erosion rate of 19 m/yr from 2007 to 2019. We use 16 high-resolution remote sensing datasets (satellite, airborne, and UAV imagery) to analyze erosion mechanisms (thermal abrasion and denudation) in relation to environmental forcings along a 1.5 km stretch of coastline during the 2018 and 2019 open water seasons. In a striking contrast, 2019 exhibited the highest mean erosion rate (34.5 m) within the 2007–2019 record, while 2018 had the second lowest (11.2 m). Block failure contributed to sub-seasonal erosion rates 6 to 21 times higher than thermal denudation, with staggered block fall timing, lag responses post-storm, and non-storm block collapse influencing overall erosion magnitude and timing. To quantify wind effects, we developed wind sums, a metric combining cumulative wind speed and directional data that can be used as a proxy for integrated storm intensity capable of incorporating lagged responses that correlated strongly with erosion at sub-seasonal and annual scales. Our findings emphasize the dominant role of wind during periods of open water and air temperature during the thaw season in driving permafrost coastline erosion dynamics, while highlighting the importance of spatiotemporally high-resolution datasets for understanding Arctic coastal change dynamics.

Alaska Beaufort Sea Coast↗

NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗

NASA NTRS1985

Development of the space shuttle body flap actuation subsystem

Development of the Body Flap Actuation Subsystem for Space Shuttles included alterations from the original design to mechanical stops, planet gears, control valves, and solenoid valves. The mechanical stops were redesigned to absorb stall load and rotating inertia of the hydraulic motors instead of only stall load. The institution of a quill shaft (torsion spring) was a successful solution. The planet gears in the geared rotary actuators developed cracks during testing. This failure was alleviated via modification to the gears. A motor pressurization - brake release timing technique was developed thru analysis and testing. This resulted in a control valve configuration which would not permit freewheeling of the body flap surface. Finally, several solenoid valve configurations were tested to obtain the desired performance. Conceptual redesigns and modifications were weighted against each other to optimize a solution. Tradeoffs were usually made between life, performance, failure tolerance, and reliability versus weight, envelope, and maintainability.

Boggs, C. R.↗

DOE OSTI2025

Functional group activation and coupling agent migration induced by plasma treatment in adhesive for enhanced toughness of metal-composite joints

Commercial adhesive paste was additionally activated using low-power oxygen plasma with different plasma exposure durations to investigate its interfacial bonding contribution in adhesively-bonded Aural-5/CFRP-PA6 double cantilever beam (DCB) joints with plasma-treated adherends. The plasma-treated adhesive showed enhanced functional peak intensities in Fourier transfer infrared spectroscopy (FTIR) as plasma exposure time was increased, and some degree of oxidation was also detected via X-ray photoelectron spectroscopy (XPS). A small molecule, dicyandiamde (coupling agent) in adhesive was migrated to adhesive layer, where double concentration of coupling agent was detected after 10 minutes of plasma treatment. As a result, characterization of the adhesive/CFRP-PA6 interface after DCB fracture showed additional chemical bonds formed through amine-initiated epoxy ring opening polymerization, as well as amide bonds and ester bonds. In conclusion, these additional bonds at the adhesive/CFRP-PA6 interfaces led to significantly increased failure extensions and fracture energies of the joints as the plasma exposure time on the adhesive increased, compared to the joints with plasma-treated adherends but non-plasma-treated adhesive as commonly seen in the literature.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Bayesian Structural Time Series for Behind-the-Meter Photovoltaic Disaggregation

Distributed photovoltaic (PV) generation often occurs ``behind the meter": a grid operator can only observe the net load, which is the sum of the gross load and distributed PV generation. This lack of observability poses a challenge to system operation at both bulk level and distribution level. The lack of real-time or near-future disaggregated estimates of gross load and PV generation will lead to over scheduling of energy production and regulation reserves, reliability constraints violations, wear and tear of controller devices, and potentially cascading failures of a system. In this paper we propose the use of a Bayesian Structural Time Series (BSTS) model with local solar irradiance measurements to disaggregate the summed PV generation and gross load signals at a downstream measurement site. BSTSs are a highly expressive model class that blends classic time series models with the powerful Bayesian state space estimation framework. Disaggregation is done probabilistically, which automatically quantifies the uncertainties of the estimated PV generation and gross load consumption. Depending on the data availability in real-time, it can be used to disaggragate PV and gross load at customer site, or can be used at the feeder level. In this paper, we focus on solving the problem at feeder level. We compare the performance of a BSTS model as well as a handful of state-of-the-art methods on a Pecan Street AMI dataset, using the National Solar Radiation Database (NSRDB) to estimate local irradiance.

bayesian structural time series↗

NASA NTRS1996

Uncertainty and Intelligence in Computational Stochastic Mechanics

Classical structural reliability assessment techniques are based on precise and crisp (sharp) definitions of failure and non-failure (survival) of a structure in meeting a set of strength, function and serviceability criteria. These definitions are provided in the form of performance functions and limit state equations. Thus, the criteria provide a dichotomous definition of what real physical situations represent, in the form of abrupt change from structural survival to failure. However, based on observing the failure and survival of real structures according to the serviceability and strength criteria, the transition from a survival state to a failure state and from serviceability criteria to strength criteria are continuous and gradual rather than crisp and abrupt. That is, an entire spectrum of damage or failure levels (grades) is observed during the transition to total collapse. In the process, serviceability criteria are gradually violated with monotonically increasing level of violation, and progressively lead into the strength criteria violation. Classical structural reliability methods correctly and adequately include the ambiguity sources of uncertainty (physical randomness, statistical and modeling uncertainty) by varying amounts. However, they are unable to adequately incorporate the presence of a damage spectrum, and do not consider in their mathematical framework any sources of uncertainty of the vagueness type. Vagueness can be attributed to sources of fuzziness, unclearness, indistinctiveness, sharplessness and grayness; whereas ambiguity can be attributed to nonspecificity, one-to-many relations, variety, generality, diversity and divergence. Using the nomenclature of structural reliability, vagueness and ambiguity can be accounted for in the form of realistic delineation of structural damage based on subjective judgment of engineers. For situations that require decisions under uncertainty with cost/benefit objectives, the risk of failure should depend on the underlying level of damage and the uncertainties associated with its definition. A mathematical model for structural reliability assessment that includes both ambiguity and vagueness types of uncertainty was suggested to result in the likelihood of failure over a damage spectrum. The resulting structural reliability estimates properly represent the continuous transition from serviceability to strength limit states over the ultimate time exposure of the structure. In this section, a structural reliability assessment method based on a fuzzy definition of failure is suggested to meet these practical needs. A failure definition can be developed to indicate the relationship between failure level and structural response. In this fuzzy model, a subjective index is introduced to represent all levels of damage (or failure). This index can be interpreted as either a measure of failure level or a measure of a degree of belief in the occurrence of some performance condition (e.g., failure). The index allows expressing the transition state between complete survival and complete failure for some structural response based on subjective evaluation and judgment.

Ayyub, Bilal M.↗

DOE OSTI2022

Resilience Design Patterns: A Structured Approach to Resilience at Extreme Scale (V.2.0)

Reliability is a serious concern for future extreme-scale high-performance computing (HPC) systems. Projections based on the current generation of HPC systems and technology roadmaps suggest the prevalence of very high fault rates in future systems. The errors resulting from these faults will propagate and generate various kinds of failures, which may result in outcomes ranging from result corruptions to catastrophic application crashes. Therefore, the resilience challenge for extreme-scale HPC systems requires coordination between various hardware and software technologies that are capable of handling a broad set of fault models at accelerated fault rates. Also, due to practical limits on power consumption in future HPC systems, they are likely to embrace innovative architectures, increasing the levels of hardware and software complexities. Therefore, the techniques that seek to improve resilience must navigate the complex trade-off space between resilience and the overheads to power consumption and performance. While the HPC community has developed various resilience solutions, application-level techniques as well as system-based solutions, the solution space of HPC resilience techniques remains fragmented. There are no formal methods to integrate the various HPC resilience techniques into composite solutions, nor are there methods to holistically evaluate the adequacy and efficacy of such solutions in terms of their protection coverage, and their performance & power efficiency characteristics. Additionally, few implementations of current resilience solutions are portable to newer architectures and software environments that will be deployed on future systems. We developed a new structured approach to the management of HPC resilience using the concept of resilience-based design patterns. In general, a design pattern is a repeatable solution to a commonly occurring problem. We identified the well-known solutions that are commonly used to deal with faults, errors and failures in HPC systems. In the initial design patterns specification (version 1.0), we described the various solutions, which address specific problems in the design of resilient HPC environments, in the form of patterns. Each pattern describes a problem caused by a fault, error or failure event in an HPC environment, and then describes the core of the solution of the problem in such a way that this solution may be adapted to different systems and implemented at different layers of the system stack. The catalog of these resilience design patterns provides designers with a collection of design elements. To construct complete resilience solutions using combinations of various patterns, we defined a framework that enhances HPC designers' understanding of the important constraints and the opportunities for the design patterns to be implemented and deployed at various layers of the system stack. The design framework is also useful for establishing interfaces and mechanisms to coordinate flexible fault management across hardware and software components, as well as to consider the trade-off between performance, resilience, and power consumption when constructing a solution. The resilience design patterns specification version 1.1 included more detailed explanations of the pattern solutions, the context in which the patterns are applicable, and the implications for hardware or software design. It also provided several additional examples and detailed case studies to demonstrate the use of patterns to build realistic solutions. In version 1.2 of the specification document, we have improved the pattern descriptions, including graphical representations of the pattern components. These improvements are largely based on critical comments, feedback and suggestions received from pattern experts and readers of the previous versions of the specification. The pattern classification has been modified to further clarify the relationships between pattern categories. This version of the specification also introduces a pattern language for resilience design patterns. The pattern language presents the patterns in the catalog as a network, revealing the relations among the resilience patterns. The language provides designers with the means to explore alternative techniques for handling a specific fault model that may have different efficiency and complexity characteristics. Using the pattern language also enables the design and implementation of comprehensive resilience solutions as a set of interconnected resilience patterns that can be instantiated across layers of the system stack. The overall goal of this work is to provide hardware and software designers, as well as the users and operators of HPC systems, a systematic methodology for the design and evaluation of resilience technologies in HPC systems that keep scientific applications running to a correct solution in a timely and cost-efficient manner despite frequent faults, errors, and failures of various types. Version 2.0 expands the resilience design pattern classification and catalog to include self-stabilization patterns and reliability, availability and performance models for each structural pattern.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

DMTN-260: Failure Modes and Error Handling for Prompt Processing

The Prompt Processing system will be responsible for processing roughly a thousand visits per night, and distributing the results in near real time, for at least ten years of Rubin Observatory operations. As such, it must be highly robust to algorithmic, network, and infrastructure failures, ranging from momentary glitches to extended downtimes. DMTN-219 introduced the initial design for the Prompt Processing framework; this document expands on the design to address expected failure modes and recovery strategies for each.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Characterization of Orography-Influenced Riming and Secondary Ice Production and Their Effects on Precipitation Rates Using Radar Polarimetry and Doppler Spectra (CORSIPP-SAIL)

The Characterization of Orography-Influenced Riming and Secondary Ice Production and Their Effects on Precipitation Rates Using Radar Polarimetry and Doppler Spectra (CORSIPP) project was conducted to help improve the understanding of precipitation formation in orographically influenced terrain. Special focus is put on the two processes of riming and secondary ice production and their external drivers. Two instruments, a polarimetric W-band simultaneous transmission simultaneous reception (STSR) Doppler cloud radar manufactured by Radiometer Physics GmbH (RPG, instrument type RPG-FMCW-94-DP), from now on named LIMRAD94, and the video in situ snowfall sensor (VISSS), were deployed at the U. S. Department of Energy Atmospheric Radiation Measurement (ARM) user facility’s Surface Atmosphere Integrated Field Laboratory (SAIL) site in Gothic, Colorado between November 2022 and June 2023 during the second SAIL winter. Note that the exact dates of data availability differ between the instruments. Both instruments arrived at Gothic on November 2, 2022, 09:20 local time. VISSS, described by Maahn et al., is equipped with two camera systems with telecentric lenses. The two cameras are at a 90° angle to each other. This configuration allows for size-independent measurements by capturing images of hydrometeors from two sides at a high frame rate of 250 Hz. With a minimum detection size of 200 μm, VISSS provides valuable insights into particle size, number, shape, complexity, and fall velocity. The VISSS was deployed on the grassland next to the ARM facility with the amazing help of the ARM employees on site. The setup started on November 2, 2022, and was finished on November 5, 2022, without major problems. VISSS measurements were started on November 6, 2022. LIMRAD94 was installed on a scaffolding platform near Orehouse (Gothic) on November 9, 2022, with the great help of RMBL staff. LIMRAD94 was mounted on a cold temperature scanner prototype. After a short test of the setup on November 9, 2022, the digital control of the scanner elevation stopped working for (at that time) unknown reasons. All attempts to resolve the problem failed. This malfunction made it impossible to operate LIMRAD94 in scanning mode. The scanner was then manually moved to zenith pointing mode and between November 10 and November 15, 2022, vertical observations for polarimetric calibration were performed. On November 15, 2022, after the polarimetric calibration was applied, the scanner was manually moved to 40° elevation with azimuthal view towards the Ka-band ARM Zenith Radar (KAZR) and measurements were continued at constant elevation. Investigation of the scanner malfunction on February 6, 2023, by Benn Schmatz revealed a disengagement between the cogwheel of the elevation motor and the cogwheel moving the scanner in elevation. This mechanical issue was temporarily solved by re-engaging the cogwheels. This made the scanner operational again for about four weeks, until mechanical force disengaged the cogwheels again on March 15, 2023. This repeated scanner failure remained undetected for about three weeks until April 8, 2023; during this time the scanner was stuck at 72° elevation. However, the radar software continued to produce data files falsely indicating that the scanner was still operational. After the scanner failure was noticed, scanning was stopped again, and we returned to constant elevation measurements. On May 15, 2023, the cogwheels of the elevation motor were secured with additional screws sent by the manufacturer. At some point in May, the cogwheels of the azimuth motor were also disengaged by mechanical force, which still allowed for range height indicator (RHI) but no plan position indicator (PPI) scans in the last weeks of the campaign. The azimuth motor was repaired in Germany after the end of the campaign. Throughout the campaign, RMBL and ARM staff kept the radar and the VISSS free of snow.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2000

Intermediate Temperature Stress Rupture of Woven SiC Fiber, BN Interphase, SiC Matrix Composites in Air

Tensile stress-rupture experiments were performed on woven Hi-Nicalon reinforced SiC matrix composites with BN interphases in air. Modal acoustic emission (AE) was used to monitor the damage accumulation in the composites during the tests and microstructural analysis was performed to determine the amount of matrix cracking that occurred for each sample. Fiber fractograph), was also performed for individual fiber failures at the specimen fracture surface to determine the strengths at which fibers failed. The rupture strengths were significantly worse than what would have been expected front the inherent degradation of the fibers themselves when subjected to similar rupture conditions. At higher applied stresses the rate of rupture "?as larger than at lower applied stresses. It was observed that the change in rupture rate corresponded to the onset of through-thickness cracking in the composites themselves. The primary cause of the sen,ere degradation was the ease with which fibers would bond to one another at their closest separation distances, less than 100 nanometers, when exposed to the environment. The near fiber-to-fiber contact in the woven tows enabled premature fiber failure over large areas of matrix cracks due to the stress-concentrations created b), fibers bonded to one another after one or a few fibers fail. i.e. the loss of global load sharing. An@, improvement in fiber-to-fiber separation of this composite system should result in improved stress- rupture properties. A model was den,eloped in order to predict the rupture life-time for these composites based on the probabilistic nature of indin,idual fiber failure at temperature. the matrix cracking state during the rupture test, and the rate of oxidation into a matrix crack. Also incorporated into the model were estimates of the stress-concentration that would occur between the outer rim of fibers in a load-bearing bundle and the unbridged region of a matrix crack after Xia et al. For the lower stresses, this source of stress-concentration was the likely cause for initial fiber failure that would trigger catastrophic failure of the composite.

Morscher, Gregory N.↗

NASA NTRS2003

Computational Study of Axisymmetric Off-Design Nozzle Flows

Computational Fluid Dynamics (CFD) analyses of axisymmetric circular-arc boattail nozzles operating off-design at transonic Mach numbers have been completed. These computations span the very difficult transonic flight regime with shock-induced separations and strong adverse pressure gradients. External afterbody and internal nozzle pressure distributions computed with the Wind code are compared with experimental data. A range of turbulence models were examined, including the Explicit Algebraic Stress model. Computations have been completed at freestream Mach numbers of 0.9 and 1.2, and nozzle pressure ratios (NPR) of 4 and 6. Calculations completed with variable time-stepping (steady-state) did not converge to a true steady-state solution. Calculations obtained using constant timestepping (timeaccurate) indicate less variations in flow properties compared with steady-state solutions. This failure to converge to a steady-state solution was the result of using variable time-stepping with large-scale separations present in the flow. Nevertheless, time-averaged boattail surface pressure coefficient and internal nozzle pressures show reasonable agreement with experimental data. The SST turbulence model demonstrates the best overall agreement with experimental data.

DalBello, Teryn↗

DOE OSTI2025

Methods to Observe Tribological Failures in Self-Mated Steel Contacts

Scuffing, a type of wear found in highly stressed or poorly lubricated contacts, is characterized by a rapid increase in friction and severe plastic deformation of the near-surface material. Scuffing has proven difficult to study because it initiates unpredictably, progresses rapidly, and typically develops within an inaccessible contact interface. Although there have been successful in-situ studies of scuffing in real-time, the transparent counter body needed for these studies changes the interactions between the surfaces and the lubricant, which affects the scuffing process in unknown ways. This paper describes the development of X-ray-compatible tribometry to study the scuffing of self-mated steels in-situ and in real-time. The method uses a crossed cylinders configuration with a thin (500 μm thick) stationary component and a small (≈200 μm) contact width to maximize X-ray interactions with atoms within the stress field generated by the contact. The resulting instrument and method are used to benchmark the scuffing response of self-mated 52,100 steel under tribologically challenging ‘oil-off’ lubrication conditions. The results demonstrate reliable scuffing in this configuration despite the relatively small contact areas and loads used. Following scuffing, gross plastic deformation was observed on both surfaces along with significant subsurface grain refinement and flow only on the stationary surface, which experienced constant contact. Interestingly, high friction initiated at specific locations of the migratory surface, which experienced intermittent contact, and then propagated across the track over time, suggesting that local conditions of the migratory surface dominated friction leading into the failure event.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Monitoring Distributed Real-Time Systems: A Survey and Future Directions

Runtime monitors have been proposed as a means to increase the reliability of safety-critical systems. In particular, this report addresses runtime monitors for distributed hard real-time systems. This class of systems has had little attention from the monitoring community. The need for monitors is shown by discussing examples of avionic systems failure. We survey related work in the field of runtime monitoring. Several potential monitoring architectures for distributed real-time systems are presented along with a discussion of how they might be used to monitor properties of interest.

Goodloe, Alwyn E.↗

DOE OSTI2025

Extrusion‐Spheronization of Mock Energetic Materials

The primary method for producing plastic bonded explosive (PBX) granules, or “prills”, has remained relatively unchanged for 70 years despite the complex nature of the process. In this work, we demonstrate the feasibility of using an extrusion‐spheronization technique to produce prills for PBX applications. We begin by detailing an inert formulation with similar properties of PBXs and then demonstrate the extrusion‐spheronization processing of these materials. A study is then performed where the spheronization process time of the extruded materials is varied and the resultant prills are morphologically characterized. Further, these prills are then pressed into high‐density articles and subject to compression testing to elucidate trends in process, properties, and performance. It was found that, for our formulation (95 wt.% melamine/5 wt.% polymer binder) and process, a spheronization time of 60 s yielded relatively uniform particles that exhibited improved poured, tapped, and pressed densities. Mechanical strength did not have a strong trend with process time as all spheronized materials had similar peak compression stress at failure. After further optimization, extrusion‐spheronization may be a promising path for future PBX formulation.

extrusion spheronization↗

DOE OSTI2022

Uncertainty Quantification Framework for Predicting Material Response with Large Number of Parameters: Application to Creep Prediction in Ferritic-Martensitic Steels Using Combined Crystal Plasticity and Grain Boundary Models

This paper presents an uncertainty quantification (UQ) framework for the physics-based model prediction of material response with a large number of parameters. The application problem presented in this work is that of predicting creep in Grade 91 steel at 600°C. The material response is defined with a physically based microstructural model with constitutive equations emulating several observed phenomena in Grade 91 and embodied into an explicit geometry mesoscale finite element model for prior austenite grains and grain boundaries. Creep within the grains and in grain boundaries are represented by crystal plasticity for dislocation motion and a physics-based model for cavity growth and nucleation, respectively. The creep behavior of this material is influenced by several parameters, some of which have a wide range of variation based on experimental data. UQ combined with microstructural modeling can discover the core microstructural causes of experimental variability, leading to improved materials with lower variability in critical long-term material properties. In this study, we investigate the model's uncertainty to identify material properties that may be modified during production to increase creep life and analyze different components of the crystal plasticity model for improvements. For this purpose, a quantity of interest is defined as time to minimum creep rate, which correlates well to the creep failure of the material. A deep neural network model was trained and validated to be used as a surrogate for the finite element model. Then, a variance-based sensitivity analysis is performed on the surrogate model to find the Sobol indices of the input parameters in respect to the output quantity of interest. The Sobol indices are used to reduce the dimensionality of the model. Generalized polynomial chaos expansion is used on the reduced basis models to propagate the uncertainty from the input parameters to the quantity of interest using the deep neural network surrogate model. These results are benchmarked against uncertainty propagation using Monte Carlo simulations. In conclusion, the UQ performed through the reduced basis model captures almost all the uncertainty in the model with significantly fewer simulations, making it possible to perform the UQ directly via simulations with the finite element model rather than surrogate machine-learned models.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Operability thresholds for thermally damaged EBW detonators

Operability thresholds that differentiate between functional RP-87 exploding bridge wire (EBW) detonators and nonfunctional RP-87 EBW detonators (duds) were determined by measuring the time delay between initiation and early wall movement (function time). The detonators were inserted into an externally heated hollow cylinder of aluminum and fired with current flow from a charged capacitor using an exploding bridge wire (EBW initiated). Functioning detonators responded like unheated pristine detonators when the function time was 4 μs or less. The operability thresholds of the detonators were characterized with a simple decomposition cookoff model calibrated using a modified version of the Sandia Instrumented Thermal Ignition (SITI) experiment. These thresholds are based on the calculated state of the PETN when the detonators fire. The operability threshold is proportional to the positive temperature difference (ΔT) between the maximum temperature within the PETN and the onset of decomposition (~406 K). Furthermore, the temperature difference alone was not sufficient to define the operability threshold. The operability threshold was also proportional to the time that the PETN had been at elevated temperatures. That is, failure was proportional to both temperature and reaction rate. The reacted gas fraction is used in the current work for the reaction correlation. Melting of PETN also had a significant effect on the operability threshold. Detonator failure occurred when the maximum temperature exceeded the nominal melting point of PETN (414 K) for 45±5 s or more.

42 ENGINEERING↗

DOE OSTI2023

Interfacial microstructure and mechanical properties of rotary inertia friction welded dissimilar 422 martensitic stainless steel to 4140 low alloy steel joints

In this work, dissimilar rotary inertia friction welds between 422 martensitic stainless steel and 4140 martensitic low-alloy steel were made to fabricate prototype heavy-duty diesel engine pistons. The influence of the inertia friction welding process and post weld heat treatment (PWHT) temperature on the interfacial microstructure evolutions and corresponding effects on mechanical properties of the 422/4140 welds were evaluated in detail. Carbon diffused from the 4140 side to the 422 side during PWHT at 650 °C for 1.5 h, causing the formation of a hard carbide-rich layer on the 422 side, and a softer but discontinuous C-depleted layer the 4140 side. PWHT at 700 °C for 1.5 h greatly accelerated C diffusion across the interface relative to 650 °C, resulting in a thicker hard carbide-rich layer and a relatively thick and continuous layer of coarse C-depleted grains (ferrite) on the 4140 side. In addition, the PWHT temperature greatly influenced the tensile properties and fracture behavior of the welds, with the 650 °C PWHT-ed samples failing predominately in a ductile manner in the 4140 heat affected zone during tensile testing. Conversely, the 700 °C PWHT specimens exhibited a strength reduction compared with the 650 °C PWHT specimens because of additional coarsening of the interfacial ferrite layer and softening of the base materials during PWHT, with brittle fracture between the hard and soft layers the predominate failure mechanism. Based on the findings, a reduced PWHT temperature and/or time, minimizing the hardness differential of the base metals, and pre-heating the 422 steel prior to welding are the potential pathways to achieve a more optimal balance between desirable tempering and stress relief of the weld microstructure and undesirable C migration across the weld interface, and to reduce the strength mismatch across the weld.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Stress accommodation in nanoscale dolan bridges designed for superconducting qubits

Josephson junctions are the principal circuit element in numerous superconducting quantum information devices and can be readily integrated into large-scale electronics. However, device integration at the wafer scale necessarily depends on having a reliable, high-fidelity, and high-yield fabrication method for creating Josephson junctions. When creating Al/AlO x based superconducting qubits, the standard Josephson junction fabrication method relies on a sub-micron suspended resist bridge, known as a Dolan bridge, which tends to be particularly fragile and can often times fracture during the resist development process, ultimately resulting in device failure. In this work, we demonstrate a unique Josephson junction lithography mask design that incorporates stress-relief channels. Our simulation results show that the addition of stress-relief channels reduces the lateral stress in the Dolan bridge by more than 70% for all the bridge geometries investigated. In practice, our novel mask design significantly increased the survivability of the bridge during device processing, resulting in 100% yield for over 100 Josephson junctions fabricated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗