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DOE OSTI2024

Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Dimensional tolerances for high-speed-machined aluminum products continue to tighten due to the demand for automated assembly of complex monolithic parts in aerospace and other industries. Understanding the contribution of inherent residual stress in wrought Al 7050-T7451 plate, common in aircraft manufacture, to distortion of high-aspect-ratio machined parts is critical but remains problematic due to the alloy's low residual stress magnitude over large geometries. Prior investigations into residual stress effects on machined part distortion suffer inadequate characterizations of the wrought material stress field, either because of low fidelity due to “slitting” methods, confounding effects in machined-layer removal methods, or small sample size when using neutron diffraction (ND). In this work, inherent residual stress is measured via ND at 860 locations in a 90.5 mm thick Al 7050-T7451 plate having dimensions 399 mm in the rolling direction and 335 mm in the transverse direction. Unlike prior studies, the ND residual stress is reconstructed using an iterative algorithm to ensure fully compatible, equilibrated 3D field prior to examining its effect on distortion. Further, the findings from simulations and experiments show that inherent residual stress alone could distort a high-aspect-ratio part beyond aerospace industry requirements, that slitting measurements may not sufficiently characterize residual stress for predicted distortion, and that parts machined from different plate thickness locations could exhibit reversed distortion patterns. Thus, research into distortion prediction that considers machining should carefully characterize and reconstruct inherent residual stress so that the coupled machining effects are accurately modeled.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Determine metrics and set targets for soil quality on agriculture residue and energy crop pathways

There are three objectives for this project: 1) support OBP in meeting MYPP stated performance goals for the Sustainability Platform, 2) develop integrated feedstock production system designs that increase total productivity of the land, decrease delivered feedstock cost to the conversion facilities, and increase environmental performance of the production system, and 3) deliver to the bioenergy community robust datasets and flexible analysis tools for establishing sustainable and viable use of agricultural residues and dedicated energy crops. The key project outcome to date has been the development and deployment of a sustainable agricultural residue removal decision support framework. The modeling framework has been used to produce a revised national assessment of sustainable residue removal potential. The national assessment datasets are being used to update national resource assessment supply curves using POLYSIS. The residue removal modeling framework has also been enhanced to support high fidelity sub-field scale sustainable removal analyses. The framework has been deployed through a web application and a mobile application. The mobile application is being used extensively in the field with industry, research, and USDA NRCS partners to support and validate sustainable residue removal decisions. The results detailed in this report have set targets for increasing soil sustainability by focusing on primary soil quality indicators (total organic carbon and erosion) in two agricultural residue management pathways and a dedicated energy crop pathway. The two residue pathway targets were set to, 1) increase residue removal by 50% while maintaining soil quality, and 2) increase soil quality by 5% as measured by Soil Management Assessment Framework indicators. The energy crop pathway was set to increase soil quality by 10% using these same indicators. To demonstrate the feasibility and impact of each of these targets, seven case studies spanning the US are presented. The analysis has shown that the feedstock production systems are capable of simultaneously increasing productivity and soil sustainability.

09 BIOMASS FUELS↗

DOE OSTI2022

Residual stress and microstructure in IN718-René41 graded superalloy fabricated by laser blown directed energy deposition

Additively printed Ni-based superalloy with a compositionally graded transition from IN718 to René41 was fabricated by laser blown-powder directed energy deposition (DED/LB-M), with the goals of meeting location-specific temperature capability and reducing component cost for hot gas path turbine components. Residual stress distribution in thin wall specimens with three sets of DED build parameters in the as-built and stress-relieved states was measured by neutron diffraction. For calculating residual stress, the calculated d0 method was found to be more appropriate as stress-free reference than using the lattice spacing measured from the stress-relief heat treated specimens. Longer dwell time (lower interpass temperature), higher energy input, smaller layer thickness resulted in a higher magnitude of tensile residual stresses at edges and compressive residual stresses at center of the specimens. The residual stress results did not show a strong dependence on graded compositions, indicating that the residual stress build-up was more geometry and process dependent. Non-destructive neutron imaging based on the attenuation coefficient qualitatively visualized the compositional variation in the bulk and showed good agreement with quantitative Electron Probe Micro-Analysis (EPMA) measurement. Grain structure, texture, and residual plastic strain along the build direction were characterized by Electron Backscatter Diffraction (EBSD). Long columnar grains with (001) preferred grain orientation were dominant along the build direction. Compositional change did not show an obvious effect on the epitaxial growth of dendrites and the continuation of the columnar grains. Residual plastic strain was relatively low in the as-built specimens.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Assessing microbial residues in soil as a potential carbon sink and moderator of carbon use efficiency

Abstract A longstanding assumption of glucose tracing experiments is that all glucose is microbially utilized during short incubations of ≤2 days to become microbial biomass or carbon dioxide. Carbon use efficiency (CUE) estimates have consequently ignored the formation of residues (non-living microbial products) although such materials could represent an important sink of glucose that is prone to stabilization as soil organic matter. We examined the dynamics of microbial residue formation from a short tracer experiment with frequent samplings over 72 h, and conducted a meta-analysis of previously published glucose tracing studies to assess the generality of these experimental results. Both our experiment and meta-analysis indicated 30–34% of amended glucose-C ( 13 C or 14 C) was in the form of residues within the first 6 h of substrate addition. We expand the conventional efficiency calculation to include residues in both the numerator and denominator of efficiency, thereby deriving a novel metric of the potential persistence of glucose-C in soil as living microbial biomass plus residues (‘carbon stabilization efficiency’). This new metric indicates nearly 40% of amended glucose-C persists in soil 180 days after amendment, the majority as non-biomass residues. Starting microbial biomass and clay content emerge as critical factors that positively promote such long term stabilization of labile C. Rapid residue production supports the conclusion that non-growth maintenance activity can illicit high demands for C in soil, perhaps equaling that directed towards growth, and that residues may have an underestimated role in the cycling and sequestration potential of C in soil.

Geyer, Kevin (ORCID:0000000252182745)↗

DOE OSTI2018

Verification and validation of residual stresses in composite structures

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, the objectives of the presented work are to demonstrate an efficient method for simulating residual stresses in composite parts, as well as the potential value of statistical methods during analyses for which material properties are unknown. Specifically, a simplified residual stress modeling approach is implemented within Sandia National Laboratories’ SIERRA/SolidMechanics code. Concurrent with the model development, bi-material composite structures are designed and manufactured to exhibit significant residual stresses. Then, the presented modeling approach is rigorously verified and validated through simulations of the bi-material composite structures’ manufacturing processes, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.

42 ENGINEERING↗

DOE OSTI2026

Comparative life cycle assessment of bioenergy in Japan from residual biomass-based wood pellets produced in the US Pacific Northwest

The US Pacific Northwest (PNW) faces an increase in wildfires due to forest overcrowding and climate change, posing significant environmental and public health risks. Traditional methods of managing surplus biomass, including prescribed burning, have increased air pollution and global warming. While in the PNW, residual woody biomass is being treated as waste, Japan’s growing demand for bio-based energy presents an opportunity to export value-added biomass as energy pellets. This study investigates whether producing wood pellets from the residual woody biomass from forest operations and sawmills for electricity generation in Japan is truly environmentally beneficial. Accordingly, we conducted a cradle-to-grave Life Cycle Assessment (LCA) to evaluate the environmental impact of residual pellets vs. coal for electricity generation. The assessment covered feedstock production, pellet processing, transportation, and combustion phases. Our findings indicate that replacing coal-based electricity in Japan with PNW residual pellet-based electricity can lower the Global Warming Potential (GWP) by about 90% for every unit of electricity displaced. Furthermore, the results show that repurposing the otherwise burnt harvest slash residues for pellet production would improve local air quality by reducing PM 2.5 and smog in the PNW. However, substituting coal with residual pellets marginally increased carcinogenic and ecotoxicity-related emissions. Based on these results, we conclude that substituting coal with residual wood pellets for electricity generation, particularly harvest-slash residual pellets, is environmentally beneficial across most impact categories, including the GWP. This research underscores how an export‑oriented pellet industry can help address the environmental challenges within the regional US wood products industry and global renewable energy supply.

Velappan, Hemalatha [Univ. of Washington, Seattle,↗

DOE OSTI2015

High-Temperature Deformation Constitutive Law for Dissimilar Weld Residual Stress Modeling: Effect of Thermal Load on Strain Hardening

Weld residual stress is one of the primary driving forces for primary water stress corrosion cracking in dissimilar metal welds (DMWs). To mitigate tensile residual stress in DMWs, it is critical to understand residual stress distribution by modeling techniques. Recent studies have shown that weld residual stress prediction using today s DMW residual stress models strongly depends on the strain-hardening constitutive model chosen. The commonly used strain-hardening models (isotropic, kinematic, and mixed) are all time-independent and inadequate to account for the time-dependent (viscous) plastic deformation at the elevated temperatures experienced during welding. For materials with profound strain-hardening, such as stainless steels and nickel-based alloys that are widely used in nuclear reactor and piping systems, the equivalent plastic strain the determinate factor of the flow stress can be highly dependent on the recovery and recrystallization processes. These processes are in turn a strong function of temperature, time, and deformation rate. Recently, the authors proposed a new temperature- and time-dependent strain-hardening constitutive model: the dynamic strain-hardening constitutive model. The application of such a model has resulted in improved weld residual stress prediction compared to the residual stress measurement results from the contour and deep-hole drilling methods. In this study, the dynamic strain-hardening behavior of Type 304 stainless steel and Alloy 82 used in pressure vessel nozzle DMWs is experimentally determined. The kinetics of the recovery and recrystallization of flow stress are derived from experiments, resulting in a semi-empirical equation as a function of pre-strain, time, and temperature that can be used for weld residual stress modeling. The method used in this work also provides an approach to study the kinetics of recovery and recrystallization of other materials with significant strain-hardening.

Yu, Xinghua↗

DOE OSTI2017

Corn Residue Use by Livestock in the United States

Corn (Zea mays L.) residue grazing or harvest provides a simple and economical practice to integrate crops and livestock, but limited information is available on how widespread corn residue utilization is practiced by US producers. In 2010, the USDA Economic Research Service surveyed producers from 19 states on corn grain and residue management practices. Total corn residue grazed or harvested was 4.87 million ha. Approximately 4.06 million ha was grazed by 11.7 million livestock (primarily cattle) in 2010. The majority of grazed corn residue occurred in Nebraska (1.91 million ha), Iowa (385,000 ha), South Dakota (361,000 ha), and Kansas (344,000 ha). Average grazing days ranged from 10 to 73 d (mean = 40 d). Corn residue harvests predominantly occurred in the central and northern Corn Belt, with an estimated 2.9 Tg of corn residue harvested across the 19 states. This survey highlights the importance of corn residue for US livestock, particularly in the western Corn Belt.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

Corn Residue Particle Size Affects Soil Surface Properties

Field operations may differentially influence crop residue size distributions, altering residue decomposition rates and soil carbon (C) and nitrogen (N) dynamics. In a laboratory microcosm study modeling corn residue distributions observed in a no-till cropping system, microbial respiration was initially (first 30 d) inversely proportional to residue particle size across four size classes. Subsequently (30–60 d), respiration in the smallest particle size decreased in relation to the larger size classes. Residue particle size significantly increased soil C levels, with the smallest sizes producing the longest-lasting effects (150 d). Smaller residue size classes initially (30 d) immobilized more soil N compared with larger size classes; however, at 150 d, the smaller size classes had mobilized increasing amounts of N while the larger size classes had progressively immobilized more N. We conclude that crop residue management operations changed characteristic residue size distributions that moderate decomposition activities and result in unique soil C and N dynamics, possibly influencing soil properties, including nutrient availability.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1994

Measurement of the fluorescence of crop residues: A tool for controlling soil erosion

Management of crop residues, the portion of a crop left in the field after harvest, is an important conservation practice for minimizing soil erosion and for improving water quality. Quantification of crop residue cover is required to evaluate the effectiveness of conservation tillage practices. Methods are needed to quantify residue cover that are rapid, accurate, and objective. The fluorescence of crop residue was found to be a broadband phenomenon with emission maxima at 420 to 495 nm for excitations of 350 to 420 nm. Soils had low intensity broadband emissions over the 400 to 690 nm region for excitations of 300 to 600 nm. The range of relative fluorescence intensities for the crop residues was much greater than the fluorescence observed of the soils. As the crop residues decompose their blue fluorescence values approach the fluorescence of the soil. Fluorescence techniques are concluded to be less ambiguous and better suited for discriminating crop residues and soils than reflectance methods. If properly implemented, fluorescence techniques can be used to quantify, not only crop residue cover, but also photosynthetic efficiency in the field.

Daughtry, C. S. T.↗

NASA NTRS2007

Evaluation of Surface Residual Stresses in Friction Stir Welds Due to Laser and Shot Peening

The effects of laser, and shot peening on the residual stresses in Friction Stir Welds (FSW) has been investigated. The surface residual stresses were measured at five different locations across the weld in order to produce an adequate residual stress profile. The residual stresses before and after sectioning the coupon from the welded plate were also measured, and the effect of coupon size on the residual stress relaxation was determined and characterized. Measurements indicate that residual stresses were not uniform along the welded plate, and large variation in stress magnitude could be exhibited at various locations along the FSW plate. Sectioning resulted in significant residual stress relaxation in the longitudinal direction attributed to the large change in dimensions in this direction. Overall, Laser and shot peening resulted in a significant reduction in tensile residual stresses at the surface of the specimens.

Hatamleh, Omar↗

NASA NTRS2015

Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

Newman, John A.↗

NASA NTRSDate not supplied

Is There A Relationship Between Cornered-Hat Methods and A Residual Approach to Estimate System Uncertainty?

Recently a relationship has been established between a now traditional residual diagnostic used to estimate observation, background and analysis error covariances of interest to data assimilation and the three-cornered hat (3CH) method. An existing extension of the traditional residual diagnostic uses residuals from a fixed lag-1 Kalman smoother to retrieve system (model) error covariance. It is thus natural to ask if an additional relationship can be established between this extended residual method and some form of cornered--hat method. The answer might seem straightforward. Unlike in the standard residual estimation case, attempting to estimate model error amounts to estimating the statistics of a residual quantity itself. As shown in this presentation, in such cases the 3CH method becomes trivial: the sought out uncertainty can be derived directly from the covariance of the residual quantity at hand. In the particular case of estimating model error, one of the corners would have to be composed of vectors providing estimates of model error; these are not typically available in practice. Therefore, at first glance the present work finds no relationship between the lag-1 smoother residual diagnostic for system error estimation and cornered--hat methods. However, the work suggests that a two-tiered 3CH might be all that is necessary for system uncertainty to be obtained with 3CH.

Ricardo Todling↗

DOE OSTI2020

Consequence Analysis of Residual Water in a Storage Canister - 20484

Recent observations from projects sponsored under the DOE-Nuclear Energy Spent Fuel and Waste Disposition campaign show that residual free water, well above the 0.4 gm-moles that correspond to a 3 torr rebound pressure after a 30-minute hold following prototypic drying, may remain within SNF canisters used for long-term dry storage. Specifically, experimental observations in an Integrated Research Project showed subzero temperatures and a local pocket of frozen water in a mockup fuel assembly subjected to an industry practiced drying process. In gas sampling and analysis from the High Burnup (HBU) Demonstration project, using a fully loaded and dried SNF canister, indicated presence of 100 g of residual water had remained in the canister. The effects of residual water in terms of potential adverse impacts on the condition of the SNF and the canister internals during long-term dry storage has been rigorously evaluated to address inadvertent residual water contents. The impact of residual water on the fuel and canister internals, with a focus on the oxidation of the cladding and of postulated exposed (breached-clad) fuel, were evaluated using an integrated set of time-dependent environmental conditions with semi-empirical materials oxidation models. An 'integration model,' with coupled sub-models, developed and previously used by the Center for Nuclear Waste Regulatory Analysis (CNWRA), was applied and expanded with improved sub-models for water radiolysis, and for cladding and fuel oxidations. Cladding oxidation models for various alloys were developed using the rate constants for various cladding alloys in the dry storage temperature range. A burnup-dependent fuel oxidation model was developed; it accounted for inhibition effect of fission products on fuel oxidation rates. The potential for extension of the initial breach flaw (1 mm hole) was evaluated by two separate mechanics criteria. In the first case, a critical cladding strain criterion was used. In the second case, a critical stress intensity was used to evaluate stability of a planar axial flaw postulate. A failure condition exists when a sufficient amount of fuel oxidation (at the postulated breached-clad location) causes fuel pellet swelling to load the cladding to meet a mechanics criterion for flaw extension. The integration model's results provide the following insights. The radiolysis-generated oxygen is consumed with a partitioning between the cladding and the fuel. The extent of cladding oxidation is no more than 2 μm additional consumption of the cladding metal even with 10 moles of residual water, indicating that changes in cladding conditions due to water are expected to be negligible. The conditions for cladding failure (breach opening size extension) directly correlates with the extent of fuel oxidation. Fuel oxidation significant to extend the breach could occur even with 5.5 moles of residual water. The results indicate that fuel oxidation vis-a-vis cladding oxidation is more likely under a higher radiation field, i.e., when radiolytic decomposition of the residual water occurs in few years compared to several decades, and that the conditions to cause failure are increased with fuel and cladding temperatures approaching the peak storage temperature limit of 400 deg. C. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Grain Orientation Dependence of the Residual Lattice Strain in a Cold Rolled Interstitial-Free Steel

The experimentally measured grain-orientation-dependent residual lattice strains, evolved in an interstitia-free steel after 70% cold rolling reduction, are studied by means of crystal elastic visco-plastic finite element simulations, which provides a very satisfactory prediction of deformation texture. The calculated residual lattice strain pole figure matches well with the experimentally measured counterpart within the highest density regions of major texture components observed. Both experimental evidence and results of modeling clearly indicate that the residual lattice strain is orientation dependent, based on comprehensive information on the evolution of residual lattice strain in various crystallographic orientations during plastic deformation. It appears that in a cold rolled material, there is a general correlation between the stresses developed just prior to unloading and the residual lattice strains in particular directions. Here, it is also shown that the cumulative plastic shear does not reveal a clear correlation with the components of residual lattice strain while presented in the normal correlation plot, however, this relationship can be better understood by means of the orientation distribution function of residual lattice strain, which can be derived from the neutron or X-ray diffraction experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A comparative analysis of residual stresses from friction stir processing of aluminum cast 380 and wrought 7075 alloy sheets: experimental characterization and modeling

Residual stresses are often overlooked in friction stir processing (FSP), but their significant impact on fatigue performance necessitates their consideration in optimizing processing parameters. The first step in this effort is understanding how process conditions influence residual stress distributions, especially across different alloys. This study focuses on determining and explaining the through-thickness residual stress variations and the effect of process temperature on the residual stress magnitude in wrought AA7075 and cast AA380.0 alloys. Additionally, for AA380.0, the impact of a second FSP pass was investigated. To achieve this, hole-drilling electronic speckle pattern interferometry (ESPI) and the thermal pseudo-mechanical (TPM) model within finite element analysis were employed to study the 3D distributions of in-plane residual stresses in processed samples under various conditions. A key finding was the varying impact of process temperatures on residual stress magnitudes. Higher process temperatures reduced stresses in AA380.0 but increased them in AA7075. Additionally, the through-thickness stress distributions differed between the two alloys. Further analysis revealed that yield stresses are crucial in explaining these phenomena and the effects of additional FSP passes. Further, this fundamental understanding will be vital in guiding the efforts to mitigate residual stresses and assess their impact on the performance of FSP aluminum alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here we report an initial reproducibility experiment focused on contour method data analysis and residual stress calculation. The experiment uses surface topography data from a physical process simulation of elastic-plastic beam bending. The simulation provides surface topography, for input to the contour method data analysis, as well as a known residual stress field with 130 MPa peak magnitude. Additionally, to increase realism, noise and specific artifacts are added to the topography data. A group of participants received the topography data (without the known residual stress), independently analyzed the data, and submitted results as a two-dimensional residual stress field. Analysis of submissions provides a group average residual stress field and the spatial distribution of reproducibility standard deviation. The group average residual stress agrees with the known stress in magnitude and spatial trend. The reproducibility standard deviation ranges from 2 to 54 MPa over the measurement plane, with an average of 5.4 MPa. Reproducibility standard deviation is smaller in the cross-section interior (≤ 5 MPa), modest near local extrema in the stress field (5 to 10 MPa), and larger near the cross-section boundaries (10 to 30 MPa). Overall, the largest values of reproducibility standard deviation (up to 54 MPa) occur in limited areas where artifacts had been added to the topography data; while some participants identified and removed these artifacts, some did not, leading to systematic differences that elevated the standard deviation.

42 ENGINEERING↗

DOE OSTI2018

Effect of Weld Consumable Conditioning on the Diffusible Hydrogen and Subsequent Residual Stress and Flexural Strength of Multipass Welded P91 Steels

P91 steel weld joint was prepared using the shielded metal arc welding process and four different conditions of weld consumable that provide the different levels of diffusible hydrogen in deposited metal. In the present research, the effects of diffusible hydrogen content on the flexural strength, lower critical stress, and tensile strength of P91 steel welds were also determined with respect to different electrode conditions. To investigate the effect of diffusible hydrogen on multipass welding, top and root side flexural tests were performed. The residual stresses (axial stress and transverse stress) were also measured using the blind hole drilling method for different conditions of welding consumable. The peak value of residual stresses was measured at the center of the weld fusion zone. The maximum value of transverse stress was measured to be 355 MPa for case II (6.21 mL/100 g of diffusible hydrogen), while the maximum axial stress was about 218 MPa for case IV (12.43 mL/100 g of diffusible hydrogen). A three-dimensional finite element simulation was also performed to predict the residual stress distribution and thermal profile along the welded joint. The experimentally determined residual stresses correlated well with the numerically estimated residual stresses. The diffusible hydrogen content was not observed to have any significant effect on the residual stresses. The corrected residual stress values were also predicted by considering the plasticity-induced error. However, the flexural performance of the welded joint was affected by the diffusible hydrogen content. The top and root flexural strength was measured to be optimum for the low level of diffusible hydrogen content, and the values decreased with an increase in diffusible hydrogen content.

36 MATERIALS SCIENCE↗