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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 1,153 records · Page 64
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Distributed Fiber Optics Measurements of Rock Deformation and Failure in Triaxial Tests

The implementation of distributed strain measurement methods in triaxial and uniaxial tests have demonstrated the development of strain localization, even at early stages. This implies that single point measurement methods are location dependent. The use of distributed methods is required not only to improve the interpreted constitutive parameters obtained from triaxial tests, but also to understand the implications of strain localization in the failure process. Here, this work uses optical fibers in triaxial tests. The developed distributed measurement method was implemented on granite, gabbro, and sandstone samples and tested under different confining pressures, reaching 200 MPa on the granite sample. Using a temporal resolution of 0.25 Hz and 5 mm of spatial resolution, the strain evolution at over 300 locations at the sample surface was measured during testing. When compared to point sensing methods, the use of optical fiber greatly increases the number of measurements at the surface of the sample, and their interpolation provides the entire deformation of the sample surface. In all the tests performed, strain localizations were revealed before failure. A three-dimensional interpretation of a test, combining an optical scan of the sample and the distributed measurements, show good correlation between the fractures and the strain localization.

58 GEOSCIENCES↗
DOE OSTI2019

Unraveling the mysterious failure of Cu/SAPO-34 selective catalytic reduction catalysts

Commercial Cu/SAPO-34 selective catalytic reduction (SCR) catalysts have experienced unexpected and quite perplexing failure. Understanding the causes at an atomic level is vital for the synthesis of more robust Cu/SAPO-34 catalysts. Here we show, via application of model catalysts with homogeneously dispersed isolated Cu ions, that Cu transformations resulting from low-temperature hydrothermal aging and ambient temperature storage can be semi-quantitatively probed with 2-dimensional pulsed electron paramagnetic resonance. Coupled with kinetics, additional material characterizations and DFT simulations, we propose the following catalyst deactivation steps: (1) detachment of Cu(II) ions from cationic positions in the form of Cu(OH)2; (2) irreversible hydrolysis of the SAPO-34 framework forming terminal Al species; and (3) interaction between Cu(OH)2 and terminal Al species forming SCR inactive, Cu-aluminate like species. Especially significant is that these reactions are greatly facilitated by condensed water molecules under wet ambient conditions, causing low temperature failure of the commercial Cu/SAPO-34 catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Effect of solid-electrolyte pellet density on failure of solid-state batteries

Abstract Despite the potentially higher energy density and improved safety of solid-state batteries (SSBs) relative to Li-ion batteries, failure due to Li-filament penetration of the solid electrolyte and subsequent short circuit remains a critical issue. Herein, we show that Li-filament growth is suppressed in solid-electrolyte pellets with a relative density beyond ~95%. Below this threshold value, however, the battery shorts more easily as the density increases due to faster Li-filament growth within the percolating pores in the pellet. The microstructural properties (e.g., pore size, connectivity, porosity, and tortuosity) of $$75\%{{{{{\rm{L}}}}}}{{{{{{\rm{i}}}}}}}_{2}{{{{{\rm{S}}}}}}-25\%{{{{{{\rm{P}}}}}}}_{2}{{{{{{\rm{S}}}}}}}_{5}$$ 75 % L i 2 S − 25 % P 2 S 5 with various relative densities are quantified using focused ion beam–scanning electron microscopy tomography and permeability tests. Furthermore, modeling results provide details on the Li-filament growth inside pores ranging from 0.2 to 2 μm in size. Our findings improve the understanding of the failure modes of SSBs and provide guidelines for the design of dendrite-free SSBs.

25 ENERGY STORAGE↗
DOE OSTI2025

Material Fracturing and Failure Simulation Datasets

Fracturing is a fundamental physics phenomena with broad relevance across multiple domains, ranging from infrastructure integrity, aerospace durability, reservoir production, and seismic events. We present a diverse dataset of simulated fracture evolution and material failure generated from two numerical solvers: the phase-field method and the combined finite-discrete element method (FDEM). These solvers differ in formulation, physical fidelity, and computational efficiency. The dataset includes five materials: PBX, anisotropic shale, tungsten, aluminum, and steel. For each, phase-field simulations span 400,000 cases: 200,000 under uniaxial tension and 200,000 under biaxial tension. The computationally expensive FDEM simulations include 90,000 split evenly among PBX, shale, and tungsten under uniaxial loading. All simulations begin with randomized initial fracture patterns. Each entry includes temporal data capturing fracture propagation dynamics. This comprehensive dataset is designed to support the development of foundational or surrogate machine learning approaches for predicting material failure. While no such models are introduced here, the dataset lays a robust foundation for advancing future research and innovation in these areas.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Self-heating and failure in scalable graphene devices

Self-heating induced failure of graphene devices synthesized from both chemical vapor deposition (CVD) and epitaxial means is compared using a combination of infrared thermography and Raman imaging. Despite a larger thermal resistance, CVD devices dissipate >3x the amount of power before failure than their epitaxial counterparts. The discrepancy arises due to morphological irregularities implicit to the graphene synthesis method that induce localized heating. As a result, morphology, rather than thermal resistance, therefore dictates power handling limits in graphene devices.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Evaluating Resilience of Water Distribution Networks to Operational Failures from Cyber-Physical Attacks

Water cyber-physical systems (CPSs) have gained increasing interest to improve operational efficiency and reliability. However, due to growing exposure to cyber-physical attacks, cybersecurity and resilience against the attacks have become significant concerns. There have been efforts to improve cybersecurity in water CPSs, yet few attempts to investigate resilience against cyber-physical attacks. This study contributes to characterizing resilience of a water CPS and investigating potential resilience strategies. An advanced resilience measure integrating withstanding, absorptive, adaptive, and restorative capability of a system is proposed and applied to the C-town water distribution network (WDN) for 15 failure set scenarios with a pressure-driven hydraulic simulation. The results provide identification of failure sets and unfavorable operational conditions that make the system more vulnerable to the cyber-physical attacks and in turn produce low resilience and capabilities. It is also found that, after recovery of a disrupted component, adjustment of overall operational interactions across system components is needed for complete restoration of disrupted functionality. The findings provide insights on infrastructure investment with resilience strategies in cyber and physical water system domains.

Shin, Sangmin↗
DOE OSTI2015

Progressive failure site generation in AlGaN/GaN high electron mobility transistors under OFF-state stress: Weibull statistics and temperature dependence

Gate leakage degradation of AlGaN/GaN high electron mobility transistors under OFF-state stress is investigated using a combination of electrical, optical, and surface morphology characterizations. The generation of leakage “hot spots” at the edge of the gate is found to be strongly temperature accelerated. The time for the formation of each failure site follows a Weibull distribution with a shape parameter in the range of 0.7–0.9 from room temperature up to 120 °C. The average leakage per failure site is only weakly temperature dependent. The stress-induced structural degradation at the leakage sites exhibits a temperature dependence in the surface morphology, which is consistent with a surface defect generation process involving temperature-associated changes in the breakdown sites.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2015

Wide-range simulation of elastoplastic wave fronts and failure of solids under high-speed loading

The aim of this paper is numerical study of deformation processes and failure of vanadium under shock-wave loading. According developed statistical theory of solid with mesoscopic defects the constitutive equations were proposed in terms of two structural variables characterizing behavior of defects ensembles: defect density tensor and structural scaling parameter. On the basis of wide-range constitutive equations the mathematical model of deformation behavior and failure of vanadium was developed taking into account the bond relaxation mechanisms, multistage of fracture and nonlinearity kinetic of defects. Results of numerical simulation allow the description of the major effects of shock wave propagation (elastic precursor decay, grow of spall strength under grow strain rate)

42 ENGINEERING↗
DOE OSTI2019

Understanding and predicting damage and failure at grain boundaries in BCC Ta

Understanding the effect of grain boundaries (GBs) on the deformation and spall behavior is critical to designing materials with tailored failure responses under dynamic loading. This understanding is hampered by the lack of in situ imaging capability with the optimum spatial and temporal resolution during dynamic experiments, as well as by the scarcity of a systematic data set that correlates boundary structure to failure, especially in BCC metals. To fill in this gap in the current understanding, molecular dynamics simulations are performed on a set of 74 bi-crystals in Ta with a [110] symmetric tilt axis. Our results show a correlation between GB misorientation angle and spall strength and also highlight the importance of GB structure itself in determining the spall strength. Specifically, we find a direct correlation between the ability of the GB to plasticity deform through slip/twinning and its spall strength. Additionally, a change in the deformation mechanism from dislocation-meditated to twinning-dominated plasticity is observed as a function of misorientation angles, which results in lowered spall strengths for high-angle GBs.

Chen, J. (ORCID:000000018633229X)↗
DOE OSTI2025

Influence of nanoscale interfaces on the dynamic deformation and spall failure of Cu–Fe alloy microstructures

Additively manufactured immiscible Cu–Fe alloys can exhibit a distribution of nanoscale interfaces due to the distribution of nanoscale clusters in the equilibrium and metastable phases. Molecular dynamics simulations investigate the role of such interfaces on the phase stability and transformation behavior during shock compression, as well as the mechanisms of damage nucleation during spall failure. The model multiphase Cu–Fe systems studied here comprise a distribution of Fe clusters in an FCC Cu matrix, as well as Cu clusters in a BCC Fe matrix. The length scales of the nanoscale clusters determine the energetics of the interfaces that can result in FCC/BCC (equilibrium) or FCC/FCC (metastable) interfaces in the Cu system matrix, and BCC/FCC (equilibrium) or BCC/BCC (metastable) interfaces in the Fe matrix. The MD simulations demonstrate that nanoscale metastable interface microstructures can induce plastic deformation and also stabilize phases or suppress phase transformations in metastable phase clusters. In contrast, equilibrium interfaces can influence phase transformation thresholds and serve as additional void nucleation sites during failure.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Active doping controls the mode of failure in dense colloidal gels

Mechanical properties of disordered materials are governed by their underlying free energy landscape. In contrast to external fields, embedding a small fraction of active particles within a disordered material generates nonequilibrium internal fields, which can help to circumvent kinetic barriers and modulate the free energy landscape. In this work, we investigate through computer simulations how the activity of active particles alters the mechanical response of deeply annealed polydisperse colloidal gels. We show that the “swim force” generated by the embedded active particles is responsible for determining the mode of mechanical failure, i.e., brittle vs. ductile. We find, and theoretically justify, that at a critical swim force the mechanical properties of the gel decrease abruptly, signaling a change in the mode of mechanical failure. The weakening of the elastic modulus above the critical swim force results from the change in gel porosity and distribution of attractive forces among gel particles, while below the critical swim force, the ductility enhancement is caused by an increase of gel structural disorder. Above the critical swim force, the gel develops a pronounced heterogeneous structure characterized by multiple pore spaces, and the mechanical response is controlled by dynamical heterogeneities. We contrast these results with those of a simulated monodisperse gel that exhibits a nonmonotonic trend of ductility modulation with increasing swim force, revealing a complex interplay between the gel energy landscape and embedded activity.

Zhou, Tingtao (ORCID:000000021766719X)↗
DOE OSTI2023

TRISO Burnup-Dependent Failure Analysis of a HTGR Design-Basis Accident Using BISON

Here, this work assesses the failure behavior of the silicon carbide (SiC) layer in TRIstructural ISOtropic (TRISO) fuel particles with BISON during both steady-state and transient conditions for the MHTGR-350 design by General Atomics. A one-dimensional BISON model for a uranium oxycarbide–bearing TRISO is developed to simulate a power level of 50 mW/particles up to 12.4% fissions per initial metal atom (FIMA). Stress predictions for the materials of interest are presented as a function of burnup, along with the SiC failure probability computed using Weibull statistics under the assumption of realistic SiC quality.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

A Study of the Impact of Peak Demand on Increasing Vulnerability of Cascading Failures to Extreme Contingency Events

The vulnerability of large power systems to cascading failures and major blackouts has become evident since the Northeast blackout in 1965. Based on analyses of the series of cascading blackouts in the past decade, the research community realized the urgent need to develop better methods, tools, and practices for performing cascading-outage analysis and for evaluating mitigations that are easily accessible by utility planning engineers. PNNL has developed the Dynamic Contingency Analysis Tool (DCAT) as an open-platform and publicly available methodology to help develop applications that aim to improve the capabilities of power planning engineers to assess the impact and likelihood of extreme contingencies and potential cascading events across their systems and interconnections. DCAT analysis will help identify potential vulnerabilities and allow study of mitigation solutions to reduce the risk of cascading outages in technically sound and effective ways. Using the DCAT capability, we examined the impacts of various load conditions to identify situations in which the power grid may encounter cascading outages that could lead to potential blackouts. This paper describes the usefulness of the DCAT tool and how it helps to understand potential impacts of load demand on cascading failures on the power system.

indexes↗
DOE OSTI2020

Fill Factor Loss in Fielded Photovoltaic Modules Due to Metallization Failures, Characterized by Luminescence and Thermal Imaging

Understanding the causes of photovoltaic module failure in the field can be achieved using spatially-resolved imaging tools in combination with current-voltage (IV) characterization. We evaluate 23 field-degraded modules by comparing their IV characteristics with module images obtained by electroluminescence, photoluminescence, UV-fluorescence, and dark lock-in thermography. We identify primarily metallization failures (metallization series resistance, solder point heating, broken fingers, disrupted interconnects) in these modules that has led to a severe drop in the fill factor and up to 35% power loss over only 2 years of deployment.

14 SOLAR ENERGY↗
DOE OSTI2021

Towards Validation of Advanced Accelerated Stress Testing Protocols through Failure Analysis and Materials Characterization

As the lifetime of photovoltaic modules increases toward the goal of 50 years, accelerated stress testing is critical to assessing the viability of newer, improved, and often cheaper materials in the field. However, the validation of accelerated testing to reproduce field failure has remained elusive. The recent developments of more advanced stress testing protocols utilizing sequential and combined stressors have provided another opportunity for validation. Using a suite of mechanical, chemical, and structural characterization methods we report the development of our approach using a known bad backsheet “AAA.” We then apply this approach to PVDF-based backsheets to further confirm the generalizability of this approach. The outcome of this work is two-fold: (1) validation of advanced accelerated testing protocols which will enable the prediction of field failures in new materials, and (2) deeper insights into the degradation mechanisms observed through the extensive characterization allowing for improved materials engineering and development.

accelerated aging↗
DOE OSTI2021

A Machine Learning-Based Vulnerability Analysis for Cascading Failures of Integrated Power-Gas Systems

This article proposes a cascading failure simulation (CFS) method and a hybrid machine learning method for vulnerability analysis of integrated power-gas systems (IPGSs). The CFS method is designed to study the propagating process of cascading failures between the two systems, generating data for machine learning with initial states randomly sampled. The proposed method considers generator and gas well ramping, transmission line and gas pipeline tripping, island issue handling and load shedding strategies. Then, a hybrid machine learning model with a combined random forest (RF) classification and regression algorithms is proposed to investigate the impact of random initial states on the vulnerability metrics of IPGSs. Extensive case studies are carried out on three test IPGSs to verify the proposed models and algorithms. Simulation results show that the proposed models and algorithms can achieve high accuracy for the vulnerability analysis of IPGSs.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Photovoltaic Inverter Failure Mechanism Estimation Using Unsupervised Machine Learning and Reliability Assessment

This article introduces a data-driven approach to assessing failure mechanisms and reliability degradation in outdoor photovoltaic (PV) string inverters. The manufacturer's stated PV inverter lifetime can vary due to the impact of operating site conditions. To address limitations in degradation estimation through accelerated testing, condition monitoring, or degradation modeling, we propose a machine learning (ML) oriented approach. Utilizing data from a 1.4 MW PV power plant operational since 2016, with 46 string PV inverters tied to the grid, we employ the unsupervised one-class support vector machine ML technique to analyze inverter and sensor data, capable of classifying humidity cycling and temperature fluctuations as dominant failure mechanisms. Utilizing the anomaly alert relationship and alert details specific to the inverter, the level of PV inverter output is considered as its availability or available reliability. Subsequently, a continuous Markov model is applied to six-month alert data, revealing an average stated reliability of 20% after 20 years of continuous operation. These results support recommendations for time-bound preventive measures to enhance PV inverter reliability under diverse outdoor conditions. Furthermore, the approach provides a nondestructive, top–down, and generalized method for analyzing any commercial PV inverter exposed to outdoor conditions, contingent on the availability of relevant data.

14 SOLAR ENERGY↗
DOE OSTI2019

Multi-degree of Freedom Energy Analysis for Identification of Failure Risk in Structural Components Subjected to Random Vibration and Shock Loading

When designing or analyzing a mechanical system, energy quantities provide insight into the severity of shock and vibration environments; however, the energy methods in the literature do not address localized behavior because energy quantities are usually computed for an entire structure. The main objective of this paper is to show how to compute the energy in the components of a mechanical system. The motivation for this work is that most systems fail functionally due to component failure, not because the primary structure was overloaded, and the ability to easily compute the spatial distribution of energy helps identify failure sensitive components. The quantity of interest is input energy. That input energy can be decoupled modally is well known. What is less appreciated is that input energy can be computed at the component level exactly, using the component effective modal mass. We show the steady state input energy can be decomposed both spatially and modally and computed using input power spectra. A numerical example illustrates the spatial and modal decomposition of input energy and its utility in identifying components at risk of damage in random vibration and shock environments. Our work shows that the modal properties of the structure and the spectral content of the input must be considered together to assess damage risk. Because input energy includes absorbed energy as well as relative kinetic energy and dissipated energy, it is the recommended energy quantity for assessing the severity for both random vibration and shock environments on a structure.

42 ENGINEERING↗