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At least 1,207 records · Page 67

Critical Review of Brazil Disk Techniques for Tensile Strength Characterization With an Emphasis on High Explosive Materials

Mechanical properties are a critical performance metric for many high explosive (HE) materials and tensile strength properties are particularly important. Direct tensile measurements using dogbone shaped samples are the gold standard but they have the disadvantage that they are fairly large and require samples machined from billets. Diametral compression, more commonly known as Brazil disk (BD) testing, is an indirect method for measuring tensile strength on smaller and more easily fabricated samples. A review of the BD literature is presented with an emphasis on tensile strength measurements in high explosive materials. BD literature is reviewed in three primary areas: (i) rocks and concrete, (ii) pharmaceutical materials, and (iii) high explosive materials. The literature for rocks/concrete is extensive and dates back over 80 years; despite this there is no consensus on the validity/accuracy of the BD technique or the optimal variant of the BD technique to employ. The pharmaceutical literature is the opposite, being limited in scope and quantity of studies. BD literature on high explosive materials falls in between, not as impressive as in the rocks/concrete community but more substantiative than in the pharmaceutical community. After the review of the literature practical parameters for HE BD testing and recommended future work is discussed.

Brazil disk↗

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↗

A numerical study of the meso-structure variability in the compaction process of prepreg platelet molded composites

Compaction deformations in a thermoplastic composite system molded from chopped prepreg platelets were analyzed to obtain statistical distributions of local distortions that define the final consolidated meso-structure. This study provides an insight into and allows quantification of the intrinsic geometric variability of the composite meso-structure that controls the variability of the effective composite mechanical properties. A two-phase viscoelastic finite element model was utilized to treat the behavior of molten prepreg platelets, which were assumed to be incompressible and inextensible in the fiber direction during processing. A two-step simulation procedure with discretely modeled platelets and platelet-to-platelet contacts is proposed. The analysis begins with a drop simulation of the uncontrolled material deposition followed by a 3D finite element analysis of the preform compaction and bulk material flow. The proposed model provides a method for generating a composite meso-structure ab initio starting from a statistical sampling of the initial conditions for platelet deposition. The predicted platelet thickness distribution, intra-platelet fiber waviness and out-of-plane platelet undulations were found to be in good agreement with experimental measurements. An estimate of the volume of resin pockets was inferred from the compaction simulation.

36 MATERIALS SCIENCE↗

Analysis of tow architecture variability in biaxially braided composite tubes

Spatial deviations in composite braid unit cell dimensions limit mechanical performance and are challenging to model. Full-field measurements of the irregular tow placement in biaxially braided composite tubes were obtained by digital image correlation. Analysis of the reconstructed tow paths showed long-range defects along the hoop direction with short-range defects dominating the biased tow direction. A route toward numerical simulation of the composite response is established by developing a 3D model of the composite using the measured tow trajectories. Finally, a comparison to previously-published triaxial braid results indicates axial tows work to constrain unit cells dimensions along the hoop direction.

3-Dimensional reinforcement↗

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗

Quantifying the effect of tow architecture variability on the performance of biaxially braided composite tubes

Targeted experiments are performed with stereoscopic digital image correlation to quantify the effect of irregular braid structure on the local surface mechanical response of carbon-fiber reinforced epoxy composite tubes. Virtual models comparing both nonuniform and uniform tow structure of the outer braid of each specimen are integrated into numerical simulations similar to experiments. Experimental and numerical results agree well. Statistical tests are used to support correlations between as-manufactured braid variation ranges to local increases in stress up to 18% compared to an ideal, uniform structure in the elastic regime. Results support improved manufacturing and modeling efforts of defect sensitive braided composites.

36 MATERIALS SCIENCE↗

A combined experimental and computational analysis of failure mechanisms in open-hole cross-ply laminates under flexural loading

In this work, integrated experimental tests and computational modeling are proposed to investigate the failure mechanisms of open-hole cross-ply carbon fiber reinforced polymer (CFRP) laminated composites. In particular, we propose two effective methods, which include width-tapered double cantilever beam (WTDCB) and fixed-ratio mixed-mode end load split (FRMMELS) tests, to obtain the experimental data more reliably. We then calibrate the traction-separation laws of cohesive zone model (CZM) used among laminas of the composites by leveraging these two methods. The experimental results of fracture energy, i.e. G Ic and G Tc , obtained from WTDCB and FRMMELS tests are generally insensitive to the crack length thus requiring no effort to accurately measure the crack tip. Moreover, FRMMELS sample contains a fixed mixed-mode ratio of G IIc /G Tc depending on the width taper ratio. Examining comparisons between experimental results of FRMMELS tests and failure surface of B–K failure criterion predicted from a curve fitting, good agreement between the predictions and experimental data has been found, indicating that FRMMELS tests are an effective method to determine mixed-mode fracture criterion. In addition, a coupled experimental-computational modeling of WTDCB, edge notched flexure, and FRMMELS tests are adopted to calibrate and validate the interfacial strengths. Finally, failure mechanisms of open-hole cross-ply CFRP laminates under flexural loading have been studied systematically using experimental and multi-scale computational analyses based on the developed CZM model. The initiation and propagation of delamination, the failure of laminated layers as well as load-displacement curves predicted from computational analyses are in good agreement with what we have observed experimentally.

36 MATERIALS SCIENCE↗

Water vapor oxidation of SiC layer in surrogate TRISO fuel particles

Under accidental conditions for high temperature gas-cooled reactors (HTGR), the SiC layer in tri-structural-isotropic (TRISO) fuel particles can be exposed to water vapor. In this study, oxidation behaviors of surrogate TRISO fuel particles were investigated in a He-20 vol% water vapor mixed atmosphere at temperatures up to 1600 °C. The growth of the crystalline oxide passivation layer with cracks and pores followed a parabolic law with time, where the maximum was 2.3 μm at 1600 °C. The oxide layer and the SiC surface under the oxide became flattened with increasing temperature, as a function of the silica viscosity and the diffusion path of water vapor. Volatilization of the oxide layer was analyzed using a mechanistic model that an inert gas in oxidizing atmospheres could influence the magnitude of volatilization. The fracture load and strength of the oxidized and thinned SiC layer were numerically estimated to decrease from 2.27 to 1.69 N and from 317 to 299 MPa, respectively, with the SiC thickness decrease from 35 to 32 μm. This prediction indicates that the oxidized SiC layer should retain fission products. Additionally, the mechanical integrity of each layer in the TRISO fuel particle after oxidation was evaluated. The results in this work provide important data for the safety analysis of accidental scenarios in HTGRs.

36 MATERIALS SCIENCE↗

Modeling the corrosion of steel casing and the damage of well cement in a borehole system

This work presents the effect of chloride-induced corrosion in an underground borehole system, specifically considering the steel casing and further damage to the surrounding cement. In the past four decades, oil well cement has been successfully used for underground construction. However, high concentrations of chloride ions gradually degrade the functionality and durability of well cement. Gasses and liquids can leak from deterioration caused by chloride ions, and thus motivate this study. The chemo-mechanical coupling diffusion model and a classical fracture mechanics model are applied. The model is validated with OPC concrete corrosion data from literature, and then applied to well cement using experimentally obtained material property data. The time when crack initiation, peak pressure, and complete fracture is reached in the model of the cement sheath provides a quantification of the expected service life of the borehole system.

36 MATERIALS SCIENCE↗

Experimental and theoretical study of the restrained shrinkage cracking of early age well cement

The shrinkage cracking occurring in oil & gas well cement material is a major factor that reduces the cement sheath integrity and impairs the durability of an underground well. Shrinkage mainly takes place in the early hydration period of the cement, and the resulting restrained shrinkage cracking can form a leaking network for oil & gas or carbon dioxide stored in an underground reservoir. It is thus important to understand the early age behavior of well cement and the leaking pathway formation in the well. This study describes the application of the digital image correlation (DIC) method as a tool to measure the strain development and crack distributions of well cement in the lab during early phase changes. A theoretical model is presented to calculate the stress distribution built up in the cement sheath during early ages of well cement hydration, which helps to interpret the experimental observations and determine the major factors influencing the cracking sequences. This study presents the whole hydration – drying shrinkage – and cracking mechanism of early age well cement under restrained ring conditions experimentally and theoretically. Finally, the results offer useful insights on the key material and geometric parameters which control the fracture of a well cementing structure.

36 MATERIALS SCIENCE↗

Transparent window film with embedded nano-shades for thermoregulation

Every year, more than 20% of the energy consumption in the United States and more than 10% of the global consumption is used towards HVAC (Heating, Ventilating, Air-Conditioning) systems in buildings. Although continued efforts in advancing renewable energy, efficient appliances, and smart building systems are desired, the most critical factors that cause extensive indoor energy consumption are thermal leakage and thermal waste generation. We demonstrate a smart window film that allows natural lighting with a clear view while blocking oblique incident sunlight to make the building interior cooler without using electricity or generating heat. Building upon the concept of, often overlooked, traditional window shades and privacy window films, we emphasize and elevate the application and impact of using magnetically arranged nanoscale material for energy conservation purpose in buildings. By embedding vertically aligned Ni flakes (VANF) in a polymer matrix film, nanoscale mirror array serve as shades to block the high-angled incident sunlight, blocking approximately 73% of total solar irradiance and bringing down the indoor temperature by 1.92 °C during the daytime in a model house while providing nearly 90% transparency. Global application was simulated by applying the respective solar angle and intensity at selected latitudes, indicating their potential. This passively energy-conserving smart film is a low cost, maintenance free, and simple product for users and easy-to-manufacture product for the industry.

36 MATERIALS SCIENCE↗

Slip delocalization and diffusion mediated carbide formation during fatigue of a nickel-base superalloy

Fatigue crack initiation at high temperatures occurs at microscopic fatigue shear bands that form near twin boundaries in polycrystalline nickel-base superalloys that contain minimal metallurgical defects. The associated dislocation sub-structure is complex and dependent on thermal and mechanical conditions. Here we show the formation of fine-scale carbide precipitates along these fatigue shear bands in a nickel-base superalloy during fatigue above 650 °C. The formation of carbide precipitates is studied using calculations of bulk and pipe diffusion. The contribution of pipe diffusion is observed to be critical in the formation of fine-scale carbides and occurs coincident with the delocalization of slip during fatigue.

36 MATERIALS SCIENCE↗

Discrete stochastic model of point defect-dislocation interaction for simulating dislocation climb

Dislocation climb is an important high temperature process in metals plasticity, responsible for the phenomena such as creep, swelling, or hardening. Climb is defined by the ability of dislocations to leave their original glide plane by interacting with point defects. As such, dislocation climb is controlled by point defect diffusion/absorption/emission, all of which involve thermal activation. The existing thermodynamically consistent models for climb are generally formulated in a continuum framework, through the definition of effective defect fluxes and climb propensities in response to thermodynamic driving forces. However, the point-wise discrete nature of vacancies (and/or self-interstitials) confers a highly discrete nature to the climb dynamics, which is also strongly affected by elastic forces. The combination of discreteness, thermal activation, and elasticity makes this process too challenging for direct atomistic methods such as molecular dynamics. Here we develop a kinetic Monte Carlo model that captures vacancy generation and transport kinetics acting in conjuction with the evolving elastic fields provided by discrete dislocation dynamics simulations. The two models are coupled via the applied stresses and stress gradients generated by dislocation structures at vacancy locations. Our simulations reveal two surprising results. First that climb is dominated by vacancy emission even when the background vacancy concentration is much higher than the equilibrium one. And, second, that climb velocities might be much faster than otherwise believed when one uses the classical theories of climb. These effects are due to the locality of vacancy-dislocation processes, which are not captured in classical treatments that assume smooth vacancy fluxes and homogeneous concentrations. We apply the method to study elementary climb processes in body-centered cubic iron and furnish climb mobility functions to be used in parametric dislocation dynamics and/or crystal plasticity simulations. Here, we apply the technique to study non-conservative plastic bypass of spherical precipitates by edge dislocations and point out the differences between our discrete approach and existing continuum formulations.

36 MATERIALS SCIENCE↗

Coupled experimental and computational study of residual stresses in additively manufactured Ti-6Al-4V components

The production of metallic parts via laser-powder bed fusion (L-PBF) additive manufacturing is rapidly growing. To use components produced via L-PBF in safety-critical applications, a high degree of confidence is required in their quality. This qualification can be supported by means of a validated thermomechanical model capable of predicting the final residual stress state and subsequent performance. In this study, we use high-energy X-ray diffraction to determine a three-dimensional residual strain and stress state in a Ti-6Al-4V L-PBF component. The experimental results are used to provide validation of simulations, showing strong quantitative agreement.

36 MATERIALS SCIENCE↗

Elucidating texture and grain morphology contributions to the micromechanical response of additively manufactured Inconel 625

Microstructural variation of additively manufactured (AM) metal components in comparison to wrought counterparts makes certification for critical applications a challenge. Microscale simulations leveraging modern computational tools may be used to supplement testing of AM microstructures, thus accelerating certification by reducing the number of experiments needed. However, as micromechanical response is closely tied to critical properties like fatigue-life and fracture, utilization of these simulations with macroscale experimental data alone is insufficient. One means to attain microscale experimental data is in situ diffraction data collected from synchrotron X-ray sources. In this work, such data were collected during in situ compression of AM Inconel 625 superalloy. Interpretation of experimental results was assisted by massive (8M element) complementary micromechanical simulations performed on sets of virtual microstructures generated using cellular automata. Together, micromechanical data from diffraction experiments and simulations were used to probe the effects of textured “track” microstructures generated during laser powder bed fusion and directional strength-to-stiffness on micromechanical response. Though fiber-averaged directional strength-to-stiffness ratios were expected to dominate given the high elastic anisotropy of the material, the combination of small variations in texture and specific grain configurations unique to AM microstructures lead to significant variability in micromechanical response after yield. The findings emphasize the importance of high-fidelity microstructural representation that captures key texture components and AM-specific morphology for property prediction of AM metals.

36 MATERIALS SCIENCE↗

Ligand assisted growth of perovskite single crystals with low defect density

A low defect density in metal halide perovskite single crystals is critical to achieve high performance optoelectronic devices. Here we show the reduction of defect density in perovskite single crystals grown by a ligand-assisted solution process with 3-(decyldimethylammonio)-propane-sulfonate inner salt (DPSI) as an additive. DPSI ligands anchoring with lead ions on perovskite crystal surfaces not only suppress nucleation in solution, but also regulate the addition of proper ions to the growing surface, which greatly enhances the crystal quality. The grown CH 3 NH 3 PbI 3 crystals show better crystallinity and a 23-fold smaller trap density of 7 × 10 10 cm -3 than the optimized control crystals. The enhanced material properties result in significantly suppressed ion migration and superior X-ray detection sensitivity of CH 3 NH 3 PbI 3 detectors of (2.6 ± 0.4) × 10 6 µC Gy -1 air cm -2 for 60 kVp X-ray and the lowest detectable dose rate reaches (5.0 ± 0.7) nGy s -1 , which enables reduced radiation dose to patients in medical X-ray diagnostics.

36 MATERIALS SCIENCE↗