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All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Popcorning Failures in Polymer and MnO2 Tantalum Capacitors

Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs in chip tantalum capacitors. The sensitivity of components to the presence of moisture during soldering is characterized by the moisture sensitivity level (MSL); however, contrary to PEMs, there is no standard procedure for establishing MSL for tantalum capacitors.The effect of absorbed moisture on soldering related degradation and failures in tantalum capacitors have not been studied properly yet, and there is no sufficient information regarding the difference in the sensitivity to soldering between polymer and MnO2 capacitors. In this work, 16 types of polymer and 9 types of MnO2 tantalum capacitors with different moisture content have been tested before and after reflow soldering. The level of moisture release during soldering has been estimated and thermo-mechanical analysis used to assess deformation of capacitorsduring soldering simulations. Results show that moisture uptake in similar parts is approximately two times greater in polymer than in MnO2 capacitors. Cracking of the case and degradation of parameters can occur in both types of parts, but MnO2 capacitors are much more likely to fail catastrophically with a short circuit and possible ignition during the first power-on cycle. This type of failure in MnO2 capacitors is lot-related, can occur even at derated voltages and relatively low levels of moisture sorption that corresponds to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage.

Capacitor↗
NASA NTRS2021

Effect of Soldering on Polymer and MnO2 Tantalum Capacitors

Soldering might have a strong effect on performance and reliability of most surface mount technology components, including tantalum capacitors. High quality tantalum capacitors are likely the only type of components where soldering simulation is the first step during screening. Nevertheless, post-soldering failures of tantalum capacitors happen and require additional analysis. Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs also in chip tantalum capacitors. The sensitivity of parts to the presence of moisture during soldering is characterized by the moisture sensitivity level (MSL); however, contrary to PEMs, there is no standard procedure for establishing MSL for tantalum capacitors. The effect of absorbed moisture on soldering related degradation and failures in tantalum capacitors have not been studied properly yet, and there is no sufficient information regarding the difference in the sensitivity to soldering between polymer and MnO2 tantalum capacitors. In this work, 16 types of polymer and 9 types of MnO2 cathodes tantalum capacitors with different moisture content have been tested before and after reflow soldering. The level of moisture release after soldering has been estimated and thermo-mechanical analysis used to assess deformation of capacitors during soldering simulations. Results show that moisture uptake in similar parts is approximately two times greater in polymer than in MnO2 capacitors. Cracking of the case and degradation of parameters can occur in both types of parts, but MnO2 capacitors are much more likely to fail catastrophically with a short circuit and possible ignition during the first power-on cycle. This type of failure in MnO2 capacitors is lot-related, can occur even at derated voltages and relatively low levels of moisture sorption corresponding to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage. Recommendations for baking and testing to establish MSL are suggested.

Alexander Teverovsky↗
DOE OSTI2024

Failure Analysis for Molten Salt Thermal Energy Storage Tanks for In-Service CSP Plants

Thermal Energy Storage (TES) is a fundamental component in concentrating solar power (CSP) plants to increase the plant's dispatchability, capacity factor, while reducing the levelized cost of electricity. In central receivers CSP plants, nitrate molten salts have been used for several years for operation temperatures of up to 565 degrees C. Despite many efforts to advance nitrate salt to higher operation temperatures (even considering a replacement with molten chloride salts) to achieve higher energy conversion efficiencies, the 565 degrees C temperature is currently considered the state-of-the art. Although molten salt tanks have been broadly deployed in commercial CSP plants worldwide, several failures have been reported in these tanks after a few months or years of operation, causing significant economic loss and mistrust in CSP technologies. Most of these failures are associated with the infancy of the technology and multiple issues related to tank design, fabrication, commissioning, and aggressive operation. A technical standard dedicated to the design and fabrication of molten nitrate TES tanks does not exist today. Current in-service molten salt tanks have been generally designed based on the American Petroleum Institute's (API) 650 and ASME Section II standards. The API 650 code provides guidelines for dimensions and fabrication for oil storage tanks up to 260 degrees C. The ASME standard provides allowable stress values for various materials at a range of temperatures and conditions. Both standards seem to be limited for molten salt TES tanks where high temperatures, thermal cycling, and transient conditions are expected. In 2020, NREL released the Concentrating Solar Power Best Practices Study (NREL/TP-5500-75763) that summarized multiple issues in CSP plants, along with potential alternatives and recommendations to address those issues based on information collected from participants representing about 80% of operating CSP plants in the world. One of the recommendations from this study was the development of accurate and validated models to evaluate the plant's transient operation, capable of capturing the effect of short-term clouds and operator response, while being flexible in being adapted to various spatial and temporal resource data. The "Failure Analysis for Molten Salt Thermal Energy Tanks for In-Service CSP Plants" project was inspired on this recommendation and was focused on (1) the development and validation of a physics-based model for a representative, commercial-scale molten salt tank, (2) performing simulations to evaluate the behavior of the tank as a function of typical plant operation conditions, (3) understanding tank failures mechanisms, (4) determining the residual stress and distortion in the tank floor after welding fabrication and evaluating their impact in the stresses developed in the tank during operation, (5) assessing the impact of key operation parameters on the temperature and stress distribution, (6) conduct a preliminary evaluation of design features to reduce stress and improve tank's reliability, and (7) estimate the tank's service life based on the stress developed under diverse operation scenarios. From the analysis conducted in the project and presented in this report, it was found that maximum stresses surpassing the yield strength point of the stainless steel (SS) 347H are developed on the tank floor near the perimeter. These large stresses are strongly influenced by the initial residual stresses and distortion of the tank floor after welding fabrication. During operation, large stresses are developed in the tank floor at high operation temperatures with large salt inventory levels during transient operation. High stresses are also related to elevated temperature gradients in the tank floor that could be attributed to insufficient mixing within the salt inflow and the salt inventory. Based on the analysis, creep is the predominant failure mechanism. However, the large stress levels could favor the plastic deformation into buckles, and crack formation due to stress relaxation cracking during cycle operation. A lifetime below 3 years was estimated for the typical plant operation conditions and a specific initial residual stress and deformation distribution of the tank floor. The estimated life agrees with the service time to failure reported in several commercial molten salt tanks. Desing and operation guidelines can be extracted from the analysis presented in this report, which could be adopted by tank manufacturers and CSP operators to advance toward an ultimate solution for tank failures by reducing residual and operational stresses to achieve a tank service life of more than 30 years. Addressing failures in molten salt TES tanks is fundamental for the CSP industry's survivability, but it is also important for other industrial and power generation applications using this technology, including nuclear and concentrating solar thermal.

14 SOLAR ENERGY↗
NASA NTRS2017

Imaging a Free-Geometry Magma Reservoir Using FEM-Based Linear Inverse Modeling of InSAR Data: Application to Rabaul Caldera, Papua New Guinea

We test an innovative inversion scheme using Green’s functions from an array of pressure sources embedded in finite-element method (FEM) models to image, without assuming an a-priori geometry, the composite and complex shape of a volcano deformation source. We invert interferometric synthetic aperture radar (InSAR) data to estimate the pressurization and shape of the magma reservoir of Rabaul caldera, Papua New Guinea. The results image the extended shallow magmatic system responsible for a broad and long-term subsidence of the caldera between 2007 February and 2010 December. Elastic FEM solutions are integrated into the regularized linear inversion of InSAR data of volcano surface displacements in order to obtain a 3-D image of the source of deformation. The Green’s function matrix is constructed from a library of forward line-of-sight displacement solutions for a grid of cubic elementary deformation sources. Each source is sequentially generated by removing the corresponding cubic elements from a common meshed domain and simulating the injection of a fluid mass flux into the cavity, which results in a pressurization and volumetric change of the fluidfilled cavity. The use of a single mesh for the generation of all FEM models avoids the computationally expensive process of non-linear inversion and remeshing a variable geometry domain. Without assuming an a-priori source geometry other than the configuration of the 3-D grid that generates the library of Green’s functions, the geodetic data dictate the geometry of the magma reservoir as a 3-D distribution of pressure (or flux of magma) within the source array. The inversion of InSAR data of Rabaul caldera shows a distribution of interconnected sources forming an amorphous, shallow magmatic system elongated under two opposite sides of the caldera. The marginal areas at the sides of the imaged magmatic system are the possible feeding reservoirs of the ongoing Tavurvur volcano eruption of andesitic products on the east side and of the past Vulcan volcano eruptions of more evolved materials on the west side. The interconnection and spatial distributions of sources correspond to the petrography of the volcanic products described in the literature and to the dynamics of the single and twin eruptions that characterize the caldera. The ability to image the complex geometry of deformation sources in both space and time can improve our ability to monitor active volcanoes, widen our understanding of the dynamics of active volcanic systems and improve the predictions of eruptions.

Inverse theory↗
NASA NTRS2017

Imaging the Complex Geometry of a Magma Reservoir Using Fem-Based Linear Inverse Modeling of InSAR Data: Application to Rabaul Caldera, Papua New Guinea

We test an innovative inversion scheme using Green’s functions from an array of pressure sources embedded in finite-element method (FEM) models to image, without assuming an a-priori geometry, the composite and complex shape of a volcano deformation source. We invert interferometric synthetic aperture radar (InSAR) data to estimate the pressurization and shape of the magma reservoir of Rabaul caldera, Papua New Guinea. The results image the extended shallow magmatic system responsible for a broad and long-term subsidence of the caldera between 2007 February and 2010 December. Elastic FEM solutions are integrated into the regularized linear inversion of InSAR data of volcano surface displacements in order to obtain a 3-D image of the source of deformation. The Green’s function matrix is constructed from a library of forward line-of-sight displacement solutions for a grid of cubic elementary deformation sources. Each source is sequentially generated by removing the corresponding cubic elements from a common meshed domain and simulating the injection of a fluid mass flux into the cavity, which results in a pressurization and volumetric change of the fluid-filled cavity. The use of a single mesh for the generation of all FEM models avoids the computationally expensive process of non-linear inversion and remeshing a variable geometry domain. Without assuming an a-priori source geometry other than the configuration of the 3-D grid that generates the library of Green’s functions, the geodetic data dictate the geometry of the magma reservoir as a 3-D distribution of pressure (or flux of magma) within the source array. The inversion of InSAR data of Rabaul caldera shows a distribution of interconnected sources forming an amorphous, shallow magmatic system elongated under two opposite sides of the caldera. The marginal areas at the sides of the imaged magmatic system are the possible feeding reservoirs of the ongoing Tavurvur volcano eruption of andesitic products on the east side and of the past Vulcan volcano eruptions of more evolved materials on the west side. The interconnection and spatial distributions of sources correspond to the petrography of the volcanic products described in the literature and to the dynamics of the single and twin eruptions that characterize the caldera. The ability to image the complex geometry of deformation sources in both space and time can improve our ability to monitor active volcanoes, widen our understanding of the dynamics of active volcanic systems and improve the predictions of eruptions.

Inverse theory↗
DOE OSTI2021

Monitoring natural gas storage using Synthetic Aperture Radar: are the residuals informative?

Estimates of line-of-sight (LOS) displacements from Interferometric Synthetic Aperture Radar (InSAR) observations serve as the basis of the long-term monitoring of an operating natural gas storage site at Honor Rancho in California. Here, an inversion algorithm is used to estimate the portion of the signal that is attributable to deformation within the gas storage reservoir, located at a depth of around 3 km. Removing this contribution produces residuals that are used to characterize the background variation is surface deformation at the gas storage facility and to determine a threshold that can signify unusually large residuals. An application to almost 7 yr of InSAR data, from 2011 until 2018, indicates that there are intervals of heightened residuals as well as brief episodes of anomalously large misfits. An examination of the spatial distributions of the individual residual LOS displacements indicates larger displacements in an alluvial valley just south of the reservoir, with rapid spatial variations in sign, indicating a rather shallow origin. Furthermore, the two anomalous events also involve rapid spatial variations in the LOS displacement residuals directly above the storage facility. The results demonstrate that the technique of extracting residuals after removing the reservoir signal is a useful approach, even in the case of this deep reservoir, and is a promising method for long-term monitoring.

03 NATURAL GAS↗
NASA NTRS1978

Very Long Baseline Interferometry Applied to Polar Motion, Relativity and Geodesy

The causes and effects of diurnal polar motion are described. An algorithm is developed for modeling the effects on very long baseline interferometry observables. Five years of radio-frequency very long baseline interferometry data from stations in Massachusetts, California, and Sweden are analyzed for diurnal polar motion. It is found that the effect is larger than predicted by McClure. Corrections to the standard nutation series caused by the deformability of the earth have a significant effect on the estimated diurnal polar motion scaling factor and the post-fit residual scatter. Simulations of high precision very long baseline interferometry experiments taking into account both measurement uncertainty and modeled errors are described.

Ma, C.↗
NASA NTRS1990

The effects of time-dependent excitation on the oscillatory motion of viscously damped laminated composite flat panels

Analytical estimates are used to describe the effects of transverse shear deformation, transverse normal stress, damping, and heterogeneity on the dynamic responses of laminated composite structures. The higher-order plate model is delineated with attention given to applications for viscously damped cross-ply symmetrically laminated plates subject to different time-history excitations. These effects are considered in the context of sonic-boom and blast loadings, and comparisons are made between the results of higher-order plate theory, first-order transverse-shear deformation, and classical theory. The results of the present higher-order model are found to be immune to the changes incurred by adding transverse viscous into the analysis. The responses of pulse-loadings due to symmetrical sonic boom and a triangular blast are found to be similar for certain times and pressure fields. It is shown that only the higher-order plate theory permits the accurate evaluation of frequency spectrum and time-history structural response of composite laminates.

Nosier, A.↗
NASA NTRS2001

Analysis and Verification of HET 1 m Mirror Deflections Due to Edge Sensor Loading

The ninety-one 1 m mirror segments which comprise the McDonald Observatory Hobby Eberly Telescope (HET) primary mirror have been observed to drift out of alignment in an unpredictable manner in response to time variant temperature deviations. A Segment Alignment Maintenance System (SAMS) is being developed to detect and correct this segment-to-segment drift using sensors mounted at the edges of the mirror segments. However, the segments were not originally designed to carry the weight of edge sensors. Thus, analyses and tests were conducted as part of the SAMS design to estimate the magnitude and shape of the edge sensor induced deformations as well as the resultant optical performance. Interferometric testing of a 26 m radius of curvature HET mirror segment was performed at the Marshall Space Flight Center using several load conditions to verify the finite element analyses.

Stallcup, Michael A.↗
DOE OSTI2022

What Can Plastic Flow Fields Tell Us About Heat Sources in Deformation Processing?

We characterize primary (shape-change) and secondary (friction) deformation, and associated temperature fields, in metal cutting and forming processes, using in situ imaging and simulation. The experimental configurations enable access to the deformation zones and die contact-interfaces, for measuring deformation, temperature, and frictional drag. Infra-red thermography reveals that the plastic strain-rate field is an excellent proxy for the deformation-induced heat sources. Both spatially confined and diffuse strain-rate fields occur, depending on the initial workpiece deformation state. When the strain rate is confined, as in pre-hardened material, the temperature modeling is much simplified, as the heat source is also now localized. However complex, microstructure-driven deformation modes, like sinuous flow in annealed metals, result in spatially diffuse strain-rate and body heat sources, more challenging to analyze. Furthermore, our unified measurements should be of value for accurately estimating the fraction of plastic dissipation that is converted into heat in large-strain deformation processes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mechanical behavior and texture evolution of WE43 magnesium-rare earth alloy in Split-Hopkinson Pressure Bar and Taylor Impact Cylinder Testing

Mechanical behavior and texture evolution of Mg rare-earth alloy WE43 is investigated for strain-rates 10 -3 /s to upwards of 10 5 /s for the two material conditions - as-cast (AC) and T6 age hardened, rolled plate (RT6). The high strain-rate behavior is tested using both Taylor cylinder impact tests (TC) and split Hopkinson pressure bar tests (SHB) and bulk textures are obtained using neutron diffraction. Unlike the quasi-static strained material, AC and RT6 SHB retained high hardening rates throughout the test, even up to 30% true strain. Moreover, the high strain-rate data revealed that the RT6 material has a much higher strength than the AC material, but similar hardening rates despite significantly different initial texture. The flow stress near yield increased up to I 0% for RT6 and up to 30% for AC as the strain-rate increased six orders of magnitude from quasi-static rates 10 -3 /s to 10 3 /s. Neither material exhibited significant plastic anisotropy over the broad range of strain rates, despite the fact that the RT6 material had a moderately strong initial texture. In the TC tests, the geometric cross-sectional changes and texture along the cylinder from the cylindrical sample foot to head are measured and from the neutron diffraction texture analysis, upper-bound estimates of twin volume fraction are obtained as well as dislocation density from analyzing diffraction peak broadening. Recorded geometrical changes along several loading directions show that the material has deformed remarkably homogeneously under impact. Analysis of deformed textures indicates that {101¯2} extension deformation twinning occurred in the RT6 condition over the range of strain rates, with an upper bound estimate of 40% twin volume fraction for approximately 0.10-0.25 true strain. The peak texture components after the impact have their c-axes closely aligned with the impact direction. As a result, these observations are presented and rationalized in the paper.

42 ENGINEERING↗
DOE OSTI2020

Core of 25 F in the rotational model

In a recent experiment, carried out at the Radioactive Isotope Beam Factory/RIKEN, the 25 F(p,2p) 24 O reaction was studied at 270 MeV/A in inverse kinematics. Derived spectroscopic factors suggest that the effective core of 25 F significantly differs from a free 24 O nucleus. We interpret these results within the particle-rotor model and show that the experimental level scheme of 25 F can be understood in the rotation-aligned coupling scheme with its 5/2$^{+}_{1}$ ground state as the bandhead of a decoupled band. Here, the excitation energies of the observed 1/2$^{+}_{1}$ and 9/2$^{+}_{1}$ states correlate strongly with the rotational energy of the effective core, seen by the odd proton, and allow us to estimate its 2 + energy at ≈3.2MeV and a moderate quadrupole deformation ϵ 2 ≈0.15. The measured fragmentation of the πd 5/2 single-particle strength is discussed, and some further experiments suggested.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS1978

Martian lithospheric thickness from elastic flexure theory

The thickness of the elastic lithosphere in the Tharsis region of Mars is estimated from effects due to the surface load of Olympus Mons. Deformation (vertical displacement) and stress are calculated using elastic flexure theory for a range of possible lithospheric thicknesses (T), modeling the lithosphere as a thin elastic shell and the interior as a Newtonian fluid. For T below 150 km, displacement and stress rise rapidly with decreasing thickness. For T near 100 km, deformation of the region surrounding the volcano would be clearly visible in the topography, and resulting tensional stresses exceeding 5 kbar should produce observable fracturing at the surface. In contrast, for T near 200 km deformation is minimal and the tensional stress, being less than a kilobar, would not result in extensive fracturing. Since significant deformation and fracturing are not observed, it is concluded that the Martian elastic lithosphere is at least 150 km in thickness. Seismic, tectonic, and gravity observations all suggest a thick Martian lithosphere as well.

Thurber, C. H.↗
NASA NTRS1990

Geodetic measurement of deformation in the Loma Prieta, California earthquake with very long baseline interferometry

VLBI measurements were conducted immediately after the Loma Prieta earthquake and compared with VLBI gathered at Monterey, San Francisco, and Point Reyes since 1983 to obtain preearthquake deformation rates with respect to a North American reference frame. The estimated displacements at Monterey and San Francisco are consistent with the static displacements predicted on the basis of a coseismic slip model in which slip on the southern segment is shallower than slip on the northern segment of the fault rupture. Cartesian positions are presented at epoch 1990.0 of a set of VLBI fiducial stations and the three mobile sites in the earthquake's vicinity.

Clark, T. A.↗
NASA NTRS2000

One Century of Tectonic Deformation Along the Sumatran Fault from Triangulation and GPS Surveys

An analysis combining historical triangulation and recent Global Positioning System (GPS) survey measurements in West and North Sumatra, Indonesia, reveals a detailed slip history along the central part of the Sumatran Fault. The arc-parallel components of the combined velocity field are consistent with slip rates inferred from GPS data, ranging from 23 to 24 mm/yr. Between 1.0 S and 1.3 N the Sumatran Fault appears to be characterized by deep locking depths, on the order of 20 km, and the occurrence of large (M (sub w) approximately 7) earthquakes. The long-term (1883-1993) strains show simple right-lateral shear, with rates similar to GPS-measured, 1989-1993 strain rates. Coseismic deformation due to the 1892 Tapanuli and 1926 Padang Panjang earthquakes, estimated from triangulation measurements taken before and after the events, indicate that the main shocks were significantly larger than previously reported. The 1892 earthquake had a likely magnitude of M (sub w) approximately equal to 7.6, while the 1926 events appear to be comparable in size to the subsequent (M approximately 7) 1943 events, and an order of magnitude higher than previously reported.

Prawirodirdjo, L.↗
NASA NTRS2000

Creep of a Silicon Nitride Under Various Specimen/Loading Configurations

Extensive creep testing of a hot-pressed silicon nitride (NC132) was performed at 1300 C in air using five different specimen/loading configurations, including pure tension, pure compression, four-point uniaxial flexure, ball-on-ring biaxial flexure, and ring-on-ring biaxial flexure. Nominal creep strain and its rate for a given nominal applied stress were greatest in tension, least in compression, and intermediate in uniaxial and biaxial flexure. Except for the case of compressive loading, nominal creep strain generally decreased with time, resulting in less-defined steady-state condition. Of the four different creep formulations - power-law, hyperbolic sine, step, redistribution models - the conventional power-law model still provides the most convenient and reasonable means to estimate simple, quantitative creep parameters of the material. Predictions of creep deformation for the case of multiaxial stress state (biaxial flexure) were made based on pure tension and compression creep data by using the design code CARES/Creep.

Choi, Sung R.↗
NASA NTRS1994

A 12,000-year record of vertical deformation across the Yellowstone caldera margin: The shorelines of Yellowstone Lake

The 600 ka Yellowstone caldera exhibits several signs of unrest, the most evident of which is historic ground deformation including both uplift and subsidence. We document deformation in the area of the southern caldera across approximately 12,000 years using the postglactic shoreline terraces of Yellowstone Lake. Raised shoreline elevations were interpreted from 230 leveling profiles surveyed across flights of terraces, with an accuracy of +/- 0.5 m. Of about 11 recognizable terraces, the five most continuous raised shorelines were correlated around the lake basin to reveal deformation patterns. Net deformation over the past approximatley 3 kyr has been dominantly up within the caldera interior and slightly down along the caldera rim, relative to the extracaldera region. This uplift is roughly similar to the historic pattern and may largely represent the effects of the most recent inflation episode. Subtraction of the total estimated magnitude of inflation in this epsiode suggests that the overall trend of postglacial deformation has been subsidence. The cause of this trend is undetermined but is most likely related to the effects of regional extension and long-term cooling within the Yellowstone caldera.

Locke, William W.↗