SEARCH · Engineering Papers

Results for “Plastic”

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 1,261 records · Page 70

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Toughening materials: enhancing resistance to fracture

It has been said that ‘God invented plasticity, but the Devil invented fracture!’ Both mechanisms represent the two prime modes of structural failure, respectively, plastic collapse and the rupture/breaking of a component, but the concept of developing materials with enhanced resistance to fracture can be difficult. This is because fracture resistance invariably involves a compromise—between strength and ductility, between strength and toughness—fundamentally leading to a ‘conflict’ between nano-/micro-structural damage and the mechanisms of toughening. Here, we examine the two major classes of such toughening: (i) intrinsic toughening, which occurs ahead of a crack tip and is motivated by plasticity—this is the principal mode of fracture resistance in ductile materials, and (ii) extrinsic toughening, which occurs at, or in the wake of, a crack tip and is associated with crack-tip shielding—this is generally the sole mode of fracture resistance in brittle materials. We briefly examine how these distinct mechanistic processes have been used to toughen synthetic materials—intrinsically in gradient materials and in multiple principal-element metallic alloys with the example of metallic glasses and high-entropy alloys, and extrinsically in ceramics with the example of ceramic-matrix composites—in comparison to Nature which has been especially adept in creating biological/natural materials which are toughened by one or both mechanistic classes, despite often consisting of constituents with meagre mechanical properties. The success of Nature has been driven by its ability to cultivate the development of materials with multiple length-scale hierarchical structures that display ingenious gradients and structural adaptability, a philosophy which we need to emulate and more importantly learn to synthesize to make structural materials of the future with unprecedented combinations of mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Using principal component analysis to distinguish different dynamic phases in superconducting vortex matter

Vortices in type-II superconductors driven over random disorder are known to exhibit a remarkable variety of distinct nonequilibrium dynamical phases that arise owing to the competition between vortex-vortex interactions, the quenched disorder, and the drive. These include pinned states, elastic flows, plastic or disordered flows, and dynamically reordered moving crystal or moving smectic states. The plastic flow phases can be particularly difficult to characterize since the flows are strongly disordered. Here, we perform principal component analysis (PCA) on the positions and velocities of vortex matter moving over random disorder for different disorder strengths and drives. We find that PCA can distinguish the known dynamic phases as well as or better than previous measures based on transport signatures or topological defect densities. In addition, PCA recognizes distinct plastic flow regimes, a slowly changing channel flow and a moving amorphous fluid flow, that do not produce distinct signatures in the standard measurements. In conclusion, our results suggest that this position and velocity-based PCA approach could be used to characterize dynamic phases in a broader class of systems that exhibit depinning and nonequilibrium phase transitions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Computing virtual dark-field X-ray microscopy images of complex discrete dislocation structures from large-scale molecular dynamics simulations

Dark-field X-ray microscopy (DFXM) is a novel diffraction-based imaging technique that non-destructively maps the local deformation from crystalline defects in bulk materials. While studies have demonstrated that DFXM can spatially map 3D defect geometries, it is still challenging to interpret DFXM images of the high-dislocation-density systems relevant to macroscopic crystal plasticity. This work develops a scalable forward model to calculate virtual DFXM images for complex discrete dislocation structure(s) (DDS) obtained from atomistic simulations. Our new DDS-DFXM model integrates a non-singular formulation for calculating the local strain from the DDS and an efficient geometrical optics algorithm for computing the DFXM image from the strain field. We apply the model to complex DDS obtained from a large-scale molecular dynamics simulation of compressive loading on single-crystal silicon. Simulated DFXM images exhibit prominent contrast for dislocation features between the multiple slip systems, demonstrating the potential of DFXM to resolve features from dislocation multiplication. In conclusion, the integrated DDS-DFXM model provides a toolbox for DFXM experimental design and image interpretation in the context of bulk crystal plasticity for a range of measurements across shock plasticity and the broader materials science community.

X-ray imaging↗

DOE OSTI2021

An Analytical Solution for the Initiation and Early Progression of Fretting Wear in Spherical Contacts

Abstract This article derives analytical solutions to calculate the wear volume at the initiation of fretting motion and its early progression over the first few oscillation cycles. The Archard-based model considers a deformable hemisphere that is contact with a deformable flat block. The material pairs investigated are special alloys, the Inconel 617/Incoloy 800H, and Inconel 617/Inconel 617. The analytical study begins with a unidirectional frictional sliding contact, where the local interfacial sliding distance and the nominal sliding distance at the initiation of gross slip are derived. The obtained analytical expressions for unidirectional sliding are then used to derive the corresponding wear volume for the initiation and early progression of gross slip and the wear volume for a general fretting cycle under elastic conditions. These analytical derivations are all verified by the finite element analysis (FEA). The FEA method and the analytical solutions render virtually identical results for both similar and dissimilar material pairs. The effects of plasticity on the wear volume under elastic–plastic conditions are also investigated. It is found that the fretting wear volumes obtained from the FEA simulations, which include plasticity, are close to those obtained from the analytical expressions for purely elastic regimes. All the results are presented in normalized forms, which can be easily generalized and applied to three-dimensional fretting wear of other material pairs.

Engineering↗

DOE OSTI2021

Melting and Ejecta Produced by High Velocity Microparticle Impacts of Steel on Tin

At sufficiently high velocities, a microparticle impacting a metal substrate can cause ejection of material from the substrate and impact-induced melting, both of which can result in erosion. Here, we directly image the impact of individual hard steel microparticles on soft tin substrates, at controlled impact velocities in the range of ~100 to 1000 m/s. By using scanning electron and laser scanning confocal microscopy, we characterize the surface morphology, depth, and volume of each impact crater. We observe a gradual onset of impact-induced melting in the craters, as well as the production of increasing amounts of ejecta from the target metal. By comparing measurements of impact and rebound velocity to an elastic-plastic model, we observe that at a high enough impact velocity, melting and ejection begin to consume additional kinetic energy beyond that expected by plastic deformation of the target material alone. By calculating the excess energy dissipation using this elastic-plastic model, we show that although this divergent behavior is associated with the onset of melting, the majority of the ejected volume must be solid rather than liquid.

Mechanics↗

DOE OSTI2024

EXPERIMENTAL VALIDATION OF THEORETICAL BURST STRENGTH SOLUTION FOR DEFECT-FREE THICK-WALLED PIPES

The burst pressure of line pipes is an important strength property required in pipeline design and integrity management. Historically, the Barlow formula in conjunction with the ultimate tensile stress (UTS) of pipeline steels were utilized to estimate the burst strength of line pipes. However, the Barlow formula did not consider the plastic flow effect for ductile steels and is applicable only to thin-walled pipes. In 2006, the present author proposed a new multiaxial plastic yield theory and obtained a theoretical Zhu-Leis solution of burst strength for defect-free thin-walled pipes in term of UTS and strain hardening exponent n of pipeline steels. The Zhu-Leis solution has been validated by various burst test data for thin-walled pipelines for a wide range of steel grades from Grade B to X120. Recently, the present author extended the Zhu-Leis theory of plasticity to thick-walled pipes and obtained the Zhu-Leis solution of burst pressure for thick-walled pipes. The proposed burst pressure solution is applicable to both thin and thick-walled pipes. To experimentally validate the proposed theoretical burst pressure solution, this paper obtains a set of burst test data for three thick-walled pipes in Grade B carbon steel with a nominal diameter of 2.375 inches and three nominal wall thicknesses, resulting in D/t = 15.4, 10.9, 6.9. Through comparisons, these burst data validate the theoretical burst pressure solution for thick-walled pipes. Moreover, two additional burst test datasets collected from literature for thin and thick-walled pipes further validate the proposed burst pressure solution for both thin and thick-walled pipes.

Zhu, Xiankui↗

DOE OSTI2021

Revealing extreme twin-boundary shear deformability in metallic nanocrystals

Metals containing abundant coherent twin boundaries (TBs) are able to sustain substantial plastic deformation without fracture due to shear-induced TB migration and sliding. Retaining ductility in these metals, however, has proven difficult because detwinning rapidly exhausts TB migration mechanisms at large deformation, whereas TB sliding was only evidenced for loading on very specific crystallographic orientations. Here, we reveal the intrinsic shear deformability of twins in nanocrystals using in situ nanomechanical testing and multiscale simulations and report extreme shear deformability through TB sliding up to 364%. Sliding-induced plasticity is manifested for orientations that are generally predicted to favor detwinning and shown to depend critically on geometric inhomogeneities. Normal and shear coupling are further examined to delineate a TB orientation-dependent transition from TB sliding to TB cracking. These dynamic observations reveal unprecedented mechanical properties in nanocrystals, which hold implications for improving metal processing by severe plastic deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Magnetic resonance insights into the heterogeneous, fractal-like kinetics of chemically recyclable polymers

Moving toward a circular plastics economy is a vital aspect of global resource management. Chemical recycling of plastics ensures that high-value monomers can be recovered from depolymerized plastic waste, thus enabling circular manufacturing. However, to increase chemical recycling throughput in materials recovery facilities, the present understanding of polymer transport, diffusion, swelling, and heterogeneous deconstruction kinetics must be systematized to allow industrial-scale process design, spanning molecular to macroscopic regimes. To develop a framework for designing depolymerization processes, we examined acidolysis of circular polydiketoenamine elastomers. We used magnetic resonance to monitor spatially resolved observables in situ and then evaluated these data with a fractal method that treats nonlinear depolymerization kinetics. This approach delineated the roles played by network architecture and reaction medium on depolymerization outcomes, yielding parameters that facilitate comparisons between bulk processes. These streamlined methods to investigate polymer hydrolysis kinetics portend a general strategy for implementing chemical recycling on an industrial scale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

High-performance reversible adhesive from PET waste for underwater, structural, and pressure-sensitive applications

Developing versatile, tough, and sustainable adhesives that function effectively in both wet and dry environments is a major challenge. Here, we report a bioinspired design for versatile, tough, and reversible adhesives upcycled from consumer poly(ethylene terephthalate) (PET) waste. Our approach uses solvent-free, room-temperature dynamic cross-linking of deconstructed PET macromonomers with a diacetoacetate cross-linker, generating a dynamic, vinylogous urethane–bonded, amphiphilic adhesive. Tunable cross-linker concentration and amphiphilicity yield versatile adhesives suitable for underwater, structural, and pressure-sensitive applications on diverse substrates. Our adhesive exhibits high lap-shear strength and work of debonding under both wet and dry conditions, outperforming common commercial adhesives. The dynamic bonds enable thermal repair, on-demand multicycle debonding/rebonding, facile removal, and chemical recycling. Our strategy of transforming plastic waste into versatile, tough, and reversible adhesives offers a sustainable solution for both plastic waste management and next-generation adhesive design while also providing a commercially viable pathway for valorizing plastic waste.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Toward polymer upcycling—adding value and tackling circularity

Plastics have revolutionized modern life, but have created a global waste crisis driven by our reliance and demand for low-cost, disposable materials. New approaches are vital to address challenges related to plastics waste heterogeneity, along with the property reductions induced by mechanical recycling. Chemical recycling and upcycling of polymers may enable circularity through separation strategies, chemistries that promote closed-loop recycling inherent to macromolecular design, and transformative processes that shift the life-cycle landscape. Polymer upcycling schemes may enable lower-energy pathways and minimal environmental impacts compared with traditional mechanical and chemical recycling. The emergence of industrial adoption of recycling and upcycling approaches is encouraging, solidifying the critical role for these strategies in addressing the fate of plastics and driving advances in next-generation materials design.

Korley, LaShanda T. J.↗

DOE OSTI2021

Chemically recyclable thermoplastics from reversible-deactivation polymerization of cyclic acetals

Identifying plastics capable of chemical recycling to monomer (CRM) is the foremost challenge in creating a sustainable circular plastic economy. Polyacetals are promising candidates for CRM but lack useful tensile strengths owing to the low molecular weights produced using current uncontrolled cationic ring-opening polymerization (CROP) methods. Here, we present reversible-deactivation CROP of cyclic acetals using a commercial halomethyl ether initiator and an indium(III) bromide catalyst. Using this method, we synthesize poly(1,3-dioxolane) (PDXL), which demonstrates tensile strength comparable to some commodity polyolefins. Depolymerization of PDXL using strong acid catalysts returns monomer in near-quantitative yield and even proceeds from a commodity plastic waste mixture. Our efficient polymerization method affords a tough thermoplastic that can undergo selective depolymerization to monomer.

Abel, Brooks A.↗

DOE OSTI2021

Calibr8 v.1.0

Calibr8 provides an application to rapidly prototype and perform material model calibration for complex plasticity models using advanced adjoint or forward sensitivity analyses for execution on massively parallel machines. These techniques can be orders of magnitude faster than traditional finite difference approaches for material model calibration. The underlying technology used in Calibr8 is automatic differentiation, which allows for the rapid implementation and testing of new plasticity models within its framework. Additionally, Calibr8 can perform adjoint-based error estimation to approximate discretization errors for user-implemented plasticity models. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. SAND2021-10630 O

Granzow, BrianN.↗

DOE OSTI2024

Exascale Dislocation Simulator

ExaDiS, or Exascale Dislocation Simulator, is a set of software modules written to enable numerical simulations of large groups of moving and interacting dislocations, line defects in crystals responsible for crystal plasticity. By tracking time evolution of sufficiently large dislocation ensembles, ExaDiS predicts plasticity response and plastic strength of crystalline materials. ExaDiS is built around a library of core functions for Discrete Dislocation Dynamics method specifically written to perform efficient computations on GPUs.

Bertin, Nicolas↗

DOE OSTI2021

Slip-free multiplication and complexity of dislocation networks in FCC metals

Abstract During plastic deformation of crystalline solids, intricate networks of dislocation lines form and evolve. To capture dislocation density evolution, prominent theories of crystal plasticity assume that 1) multiplication is driven by slip in active slip systems and 2) pair-wise slip system interactions dominate network evolution. In this work, we analyze a massive database of over 100 discrete dislocation dynamics simulations (with cross-slip suppressed), and our findings bring both of these assumptions into question. We demonstrate that dislocation multiplication is commonly observed on slip systems with no applied stress and no plastic strain rate, a phenomenon we refer to as slip-free multiplication. We show that while the formation of glissile junctions provides one mechanism for slip-free multiplication, additional mechanisms which account for the influence of coplanar interactions are needed to fully explain the observations. Unlike glissile junction formation which results from a binary reaction between a pair of slip systems, these new multiplication mechanisms require higher order reactions that lead to complex network configurations. While these complex configurations have not been given much attention previously, they account for about 50% of the line intersections in our database.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Discovery of AMPX Thermal Scattering Law Processing Issue for Solid Moderators

The 2020 edition of The International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook includes a newly produced plastic-moderated evaluation, identified as PU-MET-MIXED-002 and referred to as PMM002. The 2021 edition should include another new plastic-moderated experiment, HEU-MET-THERM-004, referred to as HMT-004. These evaluations are of particular interest, as PMM-002 is moderated with polyethylene, and HMT-004 is moderated with polymethyl methacrylate (Lucite), allowing for investigation of the differences in the thermal scattering laws (TSLs) available for these materials. ENDF/B-VIII.0 includes newly produced data for 1 H-based scattering materials, including Lucite and yttrium hydride. Other available 1 H TSLs include polyethylene, light water, zirconium hydride. The unbound 1 H (free-gas) cross sections were also used. ENDF/B-VIII.0 also includes revisions made to the ENDF/B-VII.1 light water and polyethylene evaluations. Zirconium hydride was unchanged from ENDF/B-VII.1. As of this writing, there are no benchmarks included in the Verified, Archived Library of Inputs and Data (VALID) that are primarily moderated with any solid moderator, so validation that includes the PMM-002 and HMT-004 evaluations would expand the coverage to two new moderators. A study was undertaken at Oak Ridge National Laboratory with two purposes: to provide validation data based on systems that are primarily moderated with polyethylene and Lucite, and to demonstrate the reactivity changes that can result from use of different 1 H TSLs in these plastic-moderated systems. The first objective was mainly to test data and code for SCALE and AMPX, whereas the second objective was to provide useful data for practitioners on the potential variability of predicted $k_{eff}$ based on TSL changes. The use of an exactly correct TSL is often not possible given the materials involved (e.g., lubricants), but this study was intended to provide some indication of the magnitude of the changes among similar materials that can manifest through application of different TSLs in hydrogenous systems over a range of different neutron energy spectra. Unfortunately, the nominal $k_{eff}$ results exposed deviations between SCALE and Monte Carlo N-Particle (MCNP). Some of the results using different TSLs were also unexpected and difficult to explain. An investigation revealed a processing issue in AMPX that was caused by an ambiguous description of the data for incoherent elastic scattering in the ENDF manual. This issue is discussed in detail in a SCALE User Notification, and it affects some solid moderators, but it does not apply to 1 H bound in water. This issue highlights the importance of validating all TSLs used in safety analysis calculations. The remainder of this paper provides a more detailed examination of the results that triggered the investigation and a summary of the findings of that investigation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Low-temperature failure mechanism of [001] niobium micropillars under uniaxial tension

The plasticity of body-centered cubic (bcc) metals is dependent of temperature as well as sample dimension at the micrometer scale, but the effects of cryogenic temperature on the plasticity and the related failure process in micron-sized bcc metals have not been studied under uniaxial tension. In this work, we utilized in situ cryogenic micro-tensile tests, transmission electron microscopy, and dislocation dynamic simulations to examine the plasticity and failure processes of [001]-oriented bcc niobium micropillars. Our study reveals that a strong suppression of cross-slip at low temperatures prevents dislocation multiplication and leads to a dislocation starvation state, at which no mobile dislocation exists due to the rapid annihilation of dislocations at free surfaces. New dislocations are then nucleated until stress concentration at a slip step creates a micro-crack, the propagation of which leads to catastrophic failure. As a result, this unique failure process results from the combined effects of sample dimension and temperature.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Background Information on ARPA-E's REUSE Program (White Paper)

Under the REUSE Topic, ARPA-E seeks to fund the development of technologies to convert high-energy materials currently going to landfills to a high-energy content liquid product capable of displacing energy imports used for fuel or chemical production. The high-energy materials include plastics (#1-7 polymers, rubber, and composites) and paper. As discussed below, we estimate 30-34 MM ton plastic, 2-6 MM ton rubber, 18 MM ton of paper, and up to 0.1 MM ton composites are potentially available annually for this purpose. These numbers may be conservative based on changes in the plastic and paper export markets. ARPA-E anticipates deployment of multiple low-cost, simple, flexible, small-scale (100-500 ton per day) regional facilities using modular plants. This scale is consistent with the sources for high-energy materials, which include ~300 Material Recovery Facilities and industrial waste sources. The assumption is that such facilities can be more economical than the paradigm of large-scale facilities making purity products, due to cost for transporting and aggregating waste and the high operating costs (OPEX) and capital cost (CAPEX) for product purification. This document gives a brief technical review for multiple potential process technologies. The review is not intended to be comprehensive or limiting, only to provide an introduction to potential Applicants.

10 SYNTHETIC FUELS↗

DOE OSTI2020

White Paper: Background Information on ARPA-E's Reuse Program

This document provides supplemental information for ARPA-E’s exploratory research program, “Recycle Underutilized Solids to Energy” (REUSE). The goal is to provide additional technical information to prospective Applicants. Further information is available in a blog interview and webinar at https://arpa-e.energy.gov/?q=news-item/trash-treasure-reuse-creates-feedstock-plastic-waste. Award information, submission requirements, evaluation criteria, and other applicable information is provided in Funding Opportunity Announcements DE-FOA-0001953 and DE-FOA-0001954 (SBIR/STTR). REUSE-specific requirements are provided in Topic K of those FOAs, and is available at https://arpa-e-foa.energy.gov/Default.aspx?Search=0001953&SearchType=#FoaIde8647d89-1cac-4b58-8622-1b04de8958c4. Under the REUSE Topic, ARPA-E seeks to fund the development of technologies to convert high-energy materials currently going to landfills to a high-energy content liquid product capable of displacing energy imports used for fuel or chemical production. The high-energy materials include plastics (#1-7 polymers, rubber, and composites) and paper. As discussed below, we estimate 30-34 MM ton plastic, 2-6 MM ton rubber, 18 MM ton of paper, and up to 0.1 MM ton composites are potentially available annually for this purpose. These numbers may be conservative based on changes in the plastic and paper export markets. ARPA-E anticipates deployment of multiple low-cost, simple, flexible, small-scale (100-500 ton per day) regional facilities using modular plants. This scale is consistent with the sources for high-energy materials, which include ~300 Material Recovery Facilities and industrial waste sources. The assumption is that such facilities can be more economical than the paradigm of large-scale facilities making purity products, due to cost for transporting and aggregating waste and the high operating costs (OPEX) and capital cost (CAPEX) for product purification. This document gives a brief technical review for multiple potential process technologies. The review is not intended to be comprehensive or limiting, only to provide an introduction to potential Applicants.

99 GENERAL AND MISCELLANEOUS↗