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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Testing and evaluation of acoustic spectrometer for nondestructive measurement of stress and location of flaws in materials
Process monitoring in laser powder bed fusion additive manufacturing can provide insights into stochastic anomalies, melt pool and plume dynamics, and part quality. Swelling, a build anomaly where overbuilt material protrudes through the powder layer after recoating, is readily detectable in post-recoat visible light images of the powder bed. Here, this work identifies several of the underlying mechanisms driving swelling formation by analyzing the influence of processing parameters, laser scan paths, and build plate locations on the presence of swelling detected in situ. Swelling near the edge of the part and swelling in the internal region of the part are shown to correlate with different process conditions. Edge and internal swelling may be driven by different phenomena, with edge swelling predominately occurring on the edge of a part facing the laser module and correlated to clusters of near-surface voids (detected with X-ray computed tomography). A larger spot size, higher laser power, and lower scan velocity also increased the presence of edge swelling. Laser spot size and scan path influenced internal swelling, which occurred preferentially with a larger spot size and in regions with large melt pools, caused by localized heat accumulation due to non-optimal processing parameters or scan path strategies. For coupons processed with a slicer-defined maximum scan vector length, swelling seldom occurred at internal vector-stripe boundaries. These results provide a mechanistic understanding of how swelling can be linked to material flaws, insight into how some instances of swelling can be avoided, and evidence supporting the use of swelling as an in situ indicator for quality assurance and part qualification.
Fracture and short circuit in the Li 7 La 3 Zr 2 O 12 (LLZO) solid electrolyte are two key issues that prevent its adoption in battery cells. In this paper, we utilize phase-field simulations that couple electrochemistry and fracture to evaluate the maximum electric potential that LLZO electrolytes can support as a function of crack density. In the case of a single crack, we find that the applied potential at the onset of crack propagation exhibits inverse square root scaling with respect to crack length, analogous to classical fracture mechanics. Here, we further find that the short-circuit potential scales linearly with crack length. In the realistic case where the solid electrolyte contains multiple cracks, we reveal that failure fits the Weibull model. The failure distributions shift to favor failure at lower overpotentials as areal crack density increases. Furthermore, when flawless interfacial buffers are placed between the applied potential and the bulk of the electrolyte, failure is mitigated. When constant currents are applied, current focuses in near-surface flaws, leading to crack propagation and short circuit. We find that buffered samples sustain larger currents without reaching unstable overpotentials and without failing. Our findings suggest several mitigation strategies for improving the ability of LLZO to support larger currents and improve operability.
Pulse-compression gratings for high-power, short-pulse laser systems are exposed to high electric fields that are further enhanced locally due to their 2D nanostructured surface. This makes them vulnerable to laser-induced damage. The present work considers the effect on electric-field modulation caused by an array of commonly found inadvertent flaws in gratings including fabrication defects, contamination particles, and laser-induced–damage initiation. These defects affect the laser-damage performance characteristics of the grating. To understand the local field-enhancement distribution due these imperfections, 3D modeling of the electric-field distribution is performed with a sufficiently high resolution of 1/74 of the laser wavelength ( λ ) while considering a volume of ≈489 λ 3 . The results provide estimates for the ensuing electric-field intensification and projected reduction of the laser-damage thresholds, as well as the anticipated pattern of damage growth initiation.
This technical letter report provides the status of an assessment undertaken by PNNL at the request of the NRC to verify the capability of periodic ASME-required volumetric examinations of reactor vessels to characterize the density and distribution of flaws of interest for applying §50.61a on a plant-by-plant basis. The PTS rule, described in the Code of Federal Regulations, Title 10, Section 50.61 (§50.61), "Fracture Toughness Requirements for Protection against Pressurized Thermal Shock Events," establishes screening criteria to ensure that the potential for a reactor vessel to fail due to a PTS event is deemed to be acceptably low. Recently, the NRC completed a research program that concluded that the risk of through-wall cracking due to a PTS event is much lower than previously estimated. The NRC subsequently developed and promulgated an alternate PTS rule, §50.61a, that can be implemented by PWR licensees. The §50.61a rule differs from §50.61 in that it requires licensees who choose to follow this alternate method to analyze the results from periodic volumetric examinations required by the ASME Code, Section XI, Rules for Inservice Inspection (ISI) of Nuclear Power Plants.
This report provides a summary of the testing and the experiments to evaluate the utility of laser ultrasonic testing (UT) in detecting and characterizing defects on the surface of steel plates before and after the application of an engineered composite patch for crack repair. Included are the detection and characterization of defects from a section of welded plate material taken from the Sandia National Laboratories’ full-size mockup of a spent nuclear fuel (SNF) dry storage canister which had been pre-flawed and exposed to deliquescent sea salt conditions for 2 years. The information includes a review of previously reported metallurgical characterization, and new work on detailed surface characterization of the corrosion attack using laser UT.
Portable probe and eddy-current-sensitive circuitry detects internal flaws or hard spot impurities in an electrically conductive tubular channel by recording the conductivity change at the defect point.
Failure analysis of flaw growth characteristics of 6Al-4V titanium forgings used in Apollo spacecraft propellant tanks
Ultrasonic radiography for weld flaw detection in butt joints of Saturn 5 S-1C stage
Cyclic and sustained load flaw growth properties of titanium alloys for pressure vessels
Plane strain cyclic flaw growth in aluminum and titanium specimens
Stress intensity factors for surface flawed fracture specimens
Reliable and accurate Delta technique, a nondestructive ultrasonics method, uses redirection of energy to detect randomly oriented imperfections in fusion butt welds. Data on flaws can be read from either an oscilloscope or a printout.
Growth of deep surface flaws in thin wall tanks of aluminum and titanium base metals
Comparison of flaw growth characteristics under cryogenic proof and ambient test conditions for Apollo titanium pressure vessels
Fracture and sustained load flaw growth characteristics for titanium alloy evaluated in nitrogen tetroxide
Growth behavior of surface-flaw type cracks in titanium alloys
Radiographic flaw detection evaluation in aluminum TIG welds