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Results for “LOADS AND STRESSES, STRUCTURAL”

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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Crashworthiness of recycled carbon fiber composite sinusoidal structures at dynamic rates

Fiber reinforced polymer composites are finding applications in the automotive space for structurally critical applications including crash management. The use of recycled carbon fiber reinforcement can greatly reduce carbon emissions. In this study, recycled carbon fiber composites were manufactured into a self-supporting geometry using three matrices: polyphenylene sulfide (PPS), acrylonitrile butadiene styrene (ABS), and a structural epoxy, and subsequently crushed between flat platens at dynamic rates ranging from 4.6 to 9.1 ms -1 at temperatures in a range of -40°C to 80°C. Load-displacement data was used to evaluate their specific energy absorption, crush efficiency, and steady-state crush stress. Further, the energy absorption of the ABS composites was strongly sensitive to temperature, while the PPS composites exhibited strong crush efficiency dependence with both rate and temperature. The epoxy composites exhibited stable crush behavior at dynamic crush rates but exhibited a dramatic reduction in crush efficiency relative to quasi-static tests. The results of this study indicate that recycled fiber composites can achieve very high energy absorption levels (50–80kJkg -1 at room temperature) that make them an excellent alternative to more expensive and less environmentally friendly continuous virgin fiber laminates.

42 ENGINEERING↗
DOE OSTI2021

A study on the creep behavior of alloy 709 using in-situ scanning electron microscopy

In this research, an experimental evaluation of creep properties of Alloy 709 in the temperature range of 750–850 °C was undertaken. Alloy 709 is a novel austenitic stainless steel with 20% Cr and 25% Ni by wt% that was developed for application in structural components of nuclear power plants. Creep rupture tests were conducted in an in-situ heating-loading and Scanning Electron Microscope (SEM) unit equipped with Electron Backscatter Diffraction (EBSD) detector and Energy Dispersive Spectroscopy (EDS). “Real-time” creep damage mechanisms of Alloy 709 at various stresses and temperatures using a flat, un-notched sample with continuously reducing cross-section is studied so that the failure and maximum creep damage occurred at the center of the sample where the in-situ SEM imaging could be focused. Accelerated creep tests at temperatures and stresses above service conditions were performed by employing multiple blocks of constant loads where the loads were increased once the sample attained constant creep rate, indicating a secondary creep regime. This technique ensures multiple data points can be obtained from the same test, saves the time required for an otherwise long-term creep test and usage of SEM. Further, Coincident Site Lattice (CSL) boundary maps were collected as control maps before testing, and the grain boundaries were observed during the creep test to understand the effect of grain boundary character on the creep damage mechanism. Void growth, grain boundary separation, and sliding were found to be the main creep mechanisms whose rate is dependent on stress and temperature. Failure mechanisms studied on the fracture surface using SEM fractography were correlated to the sample surface observations to create complementary information to better understand the underline creep mechanism of Alloy 709.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been developed to optimize the microstructure of short fiber thermoplastic composites (SFTs)with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. Here, the current work examines the efficacy of the ‘passive’ infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σ uts ) and IRT (≈54.1%σ uts ) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 hours of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.

42 ENGINEERING↗
DOE OSTI2023

Structural design challenges and implications for high temperature concentrating solar power receivers

High operating temperatures along with diurnal cycling and high operating stresses bring many material and engineering challenges for concentrated solar power (CSP) receivers. Current design rules in ASME Boiler and Pressure Vessel (B&PV) Code for high temperature structural components were not intended for CSP components. The paper reviews the design rules in several sections of ASME B&PV Code in terms of their applicability in designing high temperature CSP receivers. With some restrictions and modifications, the conditions assumed in the design rules in Section III, Division 5 of ASME B&PV Code are found to closely resemble the loading conditions of CSP receiver, including accounting for the interaction between creep and fatigue damage. Further, the paper applies the proposed design rules to an external tubular receiver design and discusses several lessons learned from the design study. The creep damage accumulation due to high thermal stresses resulting from circumferentially non-uniform flux distribution is found to control the design of CSP receivers. Several mitigation actions to improve the design life of receivers are also discussed.

14 SOLAR ENERGY↗
DOE OSTI2020

Recent developments in catalyst-related PEM fuel cell durability

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. Furthermore, while the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

25 ENERGY STORAGE↗
DOE OSTI2025

Effect of Fatigue on the Capacity and Performance of Structural Concrete

The goal of this project was to enhance the understanding of the fatigue behavior of concrete structures for the purpose of improving the design and assessment of towers and foundations that support wind turbines, which must endure repeated loadings from wind, waves, operations, and other dynamic effects that cause material degradation. This was achieved through physical experiments, a review of the technical literature, and collaboration with experts in key subject areas. The project produced a comprehensive database of publicly available fatigue data, several technical papers presenting the research findings, and two Technotes to be published by the American Concrete Institute that advance best practices in fatigue testing and enable the development of concrete-specific fatigue (S-N) (stress-life) curves. These contributions are expected to enhance the durability and cost-effectiveness of wind turbine support structures.

17 WIND ENERGY↗
DOE OSTI2021

Sulfurized Polyacrylonitrile (SPAN): Changes in Mechanical Properties during Electrochemical Lithiation

Sulfurized polyacrylonitrile (SPAN) is a promising material for stable lithium-sulfur (Li-S) batteries that can potentially satisfy the demand for high-density energy storage devices for electric vehicles (EVs). However, important physical and chemical properties of the SPAN cathode material are not yet well understood. For example, the SPAN mechanical behavior that depends on the structure and chemistry of the material generated during synthesis, and the mechanical response evolution during battery discharge have been scarcely investigated. This work addresses the effects of electrochemical lithiation on the SPAN mechanical integrity via uniaxial tensile loading tests using molecular dynamics with the ReaxFF potential. Here, we evaluate the volume expansion, Young’s modulus, yield strength, and ultimate tensile strength with increasing lithium contents. Our results show how the degree of graphitization of the carbonized skeleton impacts the SPAN ability to withstand the volume expansion-induced structural stresses upon lithiation. We describe the fracture mechanisms and find out a ductility loss with increasing lithium contents

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

A combined ensemble-volume average homogenization method for lattice structures with defects under dynamic and static loading

In the study of lattices structures, both experiments and numerical simulations are often conducted with small samples. Using combined ensemble and volume averaging, this work introduces a method to extract a macroscopic constitutive response of a lattice material from numerical simulations performed in periodic domains. The domain size needed to obtain statistically accurate results is investigated. Similar to molecular dynamics, the concept of the virial stress is introduced after homogenized equations are derived using the ensemble averaging method. Under static conditions, the virial stress is shown to agree with the volume averaged solid stress. Using the homogenization method, constitutive relations for this stress can be obtained from systems with uniform strains. Application of such obtained constitutive relations to more general cases results in an error proportional to the square of the ratio between the lattice length scale and the macroscopic length scale. Taking advantage of this property, numerical simulations are performed in systems with a uniform gradient of the average velocity. The volume average method is then used to accelerate convergence when studying lattices with defects. To avoid the artificial numerical time scale from the size of a representative volume element divided by the wave speed, a numerical scheme is developed to enforce a spatially uniform velocity gradient within the computational domain while allowing fluctuations of the velocity or displacement to develop naturally. To account for probability distribution of lattice defects, the stress is calculated as the ensemble-volume averaged value. For dynamic systems, energy dissipation properties are also studied.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Performance and wake flow characterization of a 1:8.7-scale reference USDOE MHKF1 hydrokinetic turbine to establish a verification and validation test database

As hydrokinetic turbine technologies continue to advance towards commercialization, public datasets on the performance characteristics for these devices and their flow field effects are invaluable to advance our understanding of these technologies and to validate analytical and numerical models. The Applied Research Laboratory at The Pennsylvania State University (ARL Penn State) collaborated with Sandia National Laboratories and the University of California at Davis to design, fabricate (at a 1:8.7 scale), and experimentally test a novel hydrokinetic turbine rotor design to provide an open platform and dataset for further study and development. The water tunnel test of this three-bladed, horizontal-axis rotor recorded power production, blade loading, the near-wake flow, cavitation effects, and noise generation. These state-of-the-art measurements demonstrate much of the complex physics associated with the flow through an unducted, horizontal-axis turbine, and they elucidate the performance characteristics and flow field effects at an unprecedented fidelity, accuracy and resolution. Measurements of powering coefficients (power, torque and thrust) as a function of tip-speed-ratio were performed. The dataset also includes unsteady measurements of driveshaft loading, blade strain, tower pressures, and radiated noise. Detailed flow mapping using laser Doppler velocimetry, and planar and stereo particle image velocimetry includes measurements of mean velocity and Reynolds stresses. Although the wake measurements are limited to less than half a diameter, they reveal the complex flow patterns in the near-wake structure of the rotor. The full database, available at the United States Department of Energy’s marine and hydrokinetic data repository, includes tunnel and model Computer Aided Design geometry files and inflow data sufficient for a “Model-the-Test” computational Verification and Validation study.

13 HYDRO ENERGY↗
DOE OSTI2023

Sputter-Deposited Mo Thin Films: Multimodal Characterization of Structure, Surface Morphology, Density, Residual Stress, Electrical Resistivity, and Mechanical Response

Multimodal datasets of materials are rich sources of information which can be leveraged for expedited discovery of process–structure–property relationships and for designing materials with targeted structures and/or properties. For this data descriptor article, we provide a multimodal dataset of magnetron sputter-deposited molybdenum (Mo) thin films, which are used in a variety of industries including high temperature coatings, photovoltaics, and microelectronics. In this dataset we explored a process space consisting of 27 unique combinations of sputter power and Ar deposition pressure. Here, the phase, structure, surface morphology, and composition of the Mo thin films were characterized by x-ray diffraction, scanning electron microscopy, atomic force microscopy, and Rutherford backscattering spectrometry. Physical properties—namely, thickness, film stress and sheet resistance—were also measured to provide additional film characteristics and behaviors. Additionally, nanoindentation was utilized to obtain mechanical load-displacement data. The entire dataset consists of 2072 measurements including scalar values (e.g., film stress values), 2D linescans (e.g., x-ray diffractograms), and 3D imagery (e.g., atomic force microscopy images). An additional 1889 quantities, including film hardness, modulus, electrical resistivity, density, and surface roughness, were derived from the experimental datasets using traditional methods. Minimal analysis and discussion of the results are provided in this data descriptor article to limit the authors’ preconceived interpretations of the data. Overall, the data modalities are consistent with previous reports of refractory metal thin films, ensuring that a high-quality dataset was generated. The entirety of this data is committed to a public repository in the Materials Data Facility.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Near wake evolution of a tidal stream turbine due to asymmetric sheared turbulent inflow with different integral length scales

Tidal stream turbines deployed at highly energetic open water sites are subjected to sheared inflow in the rotor plane. The inflow shear is expected to cause asymmetric loading on the rotor blades and affect the downstream wake. In the current study, two different turbulent inflow conditions, static-high shear and dynamic shear, were generated via an active-grid turbulence generator. A 1:20 scaled three-bladed horizontal axis tidal turbine model was tested in those conditions. The results were compared to a quasi-laminar case with no imposed turbulence or shear. The results show that the high shear reduces the average performance, with a drop of up to 16% in the optimal power coefficient. Besides, the shear profiles increase torque fluctuations and induce significant differences in wake hydrodynamics between the high-speed (upper) and low-speed (lower) regions. The large integral length scales further enhance the load fluctuations perceived by the rotor but have a negligible effect on the mean wake field quantities and the wake recovery. The lower half region featured a faster breakdown of tip vortex structure and a rapid drop of swirl number, a phenomenon conjectured to be a consequence of the strong turbulence intensities and Reynolds stresses in the lower half region. Furthermore, the sheared turbulent inflow also results in a very intensive energy redistribution process towards large-scale, low-frequency motions, which is important to the downstream turbines.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Unlocking large compressive strains in thin active elastocaloric layers

Elastocaloric cooling attracts broad interest and rapidly growing attention due to its potential for high efficiency and low environmental impact. While it is common knowledge that triggering reversible entropy and temperature changes with stress applied in compression prevents rapid failures of materials, realizing this regime in elastocaloric systems is highly challenging because nearly all geometries suited for efficient heat transfer are prone to buckling even under modest loads. This work describes a concept of a novel composite, where an active NiTi layer is embedded into a polymer support structure such that the elastocaloric material is entirely in compression when the assembly is subjected to bending. The active layer achieves 8.1 K temperature change at 2.5% compressive strain without buckling. After 10,000 cycles at 2% compressive strain, the composite maintains mechanical integrity without degradation of the elastocaloric effect. The results demonstrate that NiTi and, potentially, other elastocalorically active materials in geometries previously thought impossible can be successfully implemented in regenerative cooling systems operating in compression.

42 ENGINEERING↗
DOE OSTI2022

Multiphysics Analyses of the Bottom Components of the 3D Printed Transformational Challenge Reactor

This research presents multi-physics analyses on the bottom components of the Transformational Challenge Reactor (TCR) facility. These components include the bottom axial reflector and the steel exit cone. The bottom axial reflector is made of pure silicon carbide elements hosting helium cooling channels These elements are 3D printed and therefore can host any arbitrary shape of the helium cooling channels. The design of the bottom reflector considers the neutronics and thermo-fluid dynamics performances as well as the manufacturing process optimization. More precisely, the best design of the bottom reflector reduces neutron leakage by avoiding straight cylindrical helium channels that facilitate neutron leakage, minimizes the helium flow pressure drop, and reduces the number of 3D printed silicon carbide pieces. The exit cone steel structure collects the hot helium from the bottom fuel assemblies and channels the cold helium to the top of the fuel assemblies. The steel simultaneous contact with hot and cold helium flows sets a large thermal gradient. Different designs of the exit cone are proposed to reduce the steel equivalent stress from the helium thermal load. The multi-physics analyses have been performed using Ansys Fluent, Ansys Mechanical, STAR-CCM+, and Serpent computer programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Spectral proper orthogonal decomposition of active wake mixing dynamics in a stable atmospheric boundary layer

Recent advancements in the use of active wake mixing (AWM) to reduce wake effects on downstream turbines open new avenues for increasing power generation in wind farms. However, a better understanding of the fluid dynamics underlying AWM is still needed to make wake mixing a reliable strategy for wind farm flow control. In this work, a spectral proper orthogonal decomposition (SPOD) is used to analyze the dynamics of coherent flow structures that are induced in the wake through blade pitch actuation. The data are generated using the ExaWind software suite to perform large eddy simulations of an NREL 2.8 MW turbine operating in a stable atmospheric boundary layer. SPOD tracks the modal behavior of flow structures from their generation in the turbine induction field through their growth in the near-wake region and to their subsequent evolution and energy transfers in the far wake. SPOD is shown to be a useful tool in the context of AWM because it translates the wavenumber and frequency inputs to the turbine controller to structures in the wake. A decomposition of the radial shear stress flux in the wake is also developed using SPOD to measure the contribution of coherent flow structures to mean flow turbulent entrainment and wake recovery. The effectiveness of AWM is connected to its ability to excite inherent structures in the wake of the turbine that arise using baseline controls. The effects of AWM on blade loading are also analyzed by connecting the axial force along the blade to the SPOD analysis of the turbine induction field. Lastly, the performance of different AWM strategies is demonstrated in a two-turbine array.

17 WIND ENERGY↗
DOE OSTI2023

Effects of rhodium doping on dislocation nucleation in a [001] SrNi 2 P 2 single crystal under spherical nanoindentation

Nanoindentation was performed on SrNi 2 P 2 single crystals and their dilute solid solutions, Sr(Ni 1–x Rh x ) 2 P 2 (x = 0 ~ 0.055), under [001] loading to investigate the effects of elemental doping on Young’s modulus and dislocation nucleation stress. The results show that Young’s modulus and the dislocation nucleation stress decrease as the Rh content increases, and their Rh content dependence also varies with the Rh content. Electron diffraction analysis and the anisotropic lattice distortion calculations revealed that a local structural transition from the orthorhombic superstructure to the tetragonal structure and local compressive residual stresses could be the main reasons for the decrease in Young’s modulus and dislocation nucleation stress, respectively. The overlap of stress–strain fields between Rh atoms and the associated local structural transition contribute to their Rh content dependence. Here, the results also indicate that elemental doping does not necessarily strengthen materials if the incipient plasticity is controlled by dislocation nucleation, unlike conventional solid solution strengthening.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Self-Sensing Composites via an Embedded 3D-Printed PVDF-MoS 2 Nanosensor for Structural Health Monitoring

Carbon fiber (CF)-reinforced epoxy composites are widely used in vehicle applications, where early damage detection is crucial for reliability and safety. To address this need, we developed a self-sensing epoxy/CF composite by embedding a PVDF-MoS 2 nanosensor via an embedded 3D printing method. By harnessing the intrinsic curing kinetics of epoxy, we tailored its rheological properties to optimize the embedded printing process, enabling precise and reliable support for sensor filaments without compromising the composite’s structural and functional integrity. Through comprehensive rheological and kinetic analysis, we established a quantitative relationship among curing temperature, conversion rate, and resulting yield modulus─defining a narrow processing window essential for successful sensor integration. Specifically, we identified that an epoxy yield modulus range of 180–294 Pa and a conversion rate below 10% are critical to support the PVDF-MoS 2 filament architecture. Here, this embedded 3D printing method produces complex and multimaterial PVDF-MoS 2 sensors within an epoxy matrix with minimal deformation and reduced postprocessing, which is scalable and adaptable for industrial applications. Under cyclic loading, the embedded sensors exhibited stable signals under constant loads and increased voltage signals in response to crack formation (17–35% higher) and catastrophic failure (1 order of magnitude higher), effectively capturing structural changes in real time. This study demonstrates the potential of PVDF-MoS 2 nanocomposite sensor materials for real-time structural health monitoring in epoxy–CF composite systems, enabling early detection of defects and stress anomalies, significantly reducing the risk of unexpected failures, and enhancing structural reliability.

PVDF-MoS2 sensor↗
DOE OSTI2021

Data Processing Package for Cyclic Integrated Reversible Bending Fatigue Testing

A data processing software package has been introduced. The package was developed using MATLAB with the aid of the Curve Fitting Toolbox. The package is made up of four modules: pre-processing, data processing for static testing, data processing for monitoring, and data processing for measurements. CIRFT data are structured with multiple levels of architecture involving group, specimen, session, and scan/block. The degree of complexity of the data structure depends on whether a test is static or cyclic.The test results are presented in figures, scatter plots, and tables. For static testing, the output in tables provides bending mechanical properties and characteristic points of moment–curvature relation: flexural rigidities in linear segments of loading and unloading stages, intersection points between characteristic segments of the curve, and equivalent stress and strain quantities. For cyclic testing, the table output lists control and fatigue life and responsive/dependent quantities including moment, curvature, flexural rigidity, flexural hysteresis, rigidity phase angle, and equivalent stresses and strains. In addition, derivatives such as half-gage length and sensor spacing correction are included. The output also provides standard deviations of the reported quantities when they are applicable or available. The data processing package can serve as a fundamental characterization tool in mechanical study of materials. The package is intended primarily for data processing for the CIRFT process and can also be used in applications for which similar testing requirements exist.

36 MATERIALS SCIENCE↗