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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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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Electronic Health Management

Accelerated aging methodologies for electrolytic components have been designed and accelerated aging experiments have been carried out. The methodology is based on imposing electrical and/or thermal overstresses via electrical power cycling in order to mimic the real world operation behavior. Data are collected in-situ and offline in order to periodically characterize the devices' electrical performance as it ages. The data generated through these experiments are meant to provide capability for the validation of prognostic algorithms (both model-based and data-driven). Furthermore, the data allow validation of physics-based and empirical based degradation models for this type of capacitor. A first set of models and algorithms has been designed and tested on the data.

Celaya, Jose R.↗
DOE OSTI2016

Thermal Aging Degradation of Cast Stainless Steels in LWR Systems

Cast austenitic stainless steels (CASSs) have been extensively used for the large components of light water reactor (LWR) power plants such as primary coolant piping and pump casing. Since a large number of massive CASS components are installed in every modern nuclear power plant, any significant degradation of CASS components will raise serious concerns on the integrity of the entire power plant. Upon the presumption that the replacement cost of such massive components is prohibitive, therefore, thorough scientific understanding and systematic monitoring the thermal aging degradation of CASS components should be essential requirements for assessing the plant safety. In the past few decades many researches have concluded that the formation of Cr-rich α-phase by Spinoidal decomposition of δ-ferrite phase, which is formed in high temperature region during cooling, is the primary mechanism for the thermal embrittlement. Cracking mechanism in the thermally-embrittled duplex stainless steels consists of cleavage initiation at ferrite and crack propagation via separation of ferrite-austenite interphase. It has been known, however, that such thermal aging embrittlement is observed only in accelerated aging conditions and the cast stainless steel grades used in nuclear plants have performed well without experiencing real embrittlement. It has been speculated that long-term thermal aging for ≥ 60 years could lead to further decomposition of designed phases and increase of precipitation. This will result in significantly increased susceptibility to embrittlement or other degradation due to thermal aging-radiation synergistic effect, irradiation-induced degradation, stress-corrosion cracking, and general corrosion. Currently, therefore, the thermal embrittlement of CASS components is one of the most serious concerns for extended operation of nuclear power plants. A scientific research is underway to address the issues related to the thermal aging degradation of CASS components. The research aims to provide knowledge-based conclusive prediction for the integrity of the CASS components of LWR power plants during extended operation up to and beyond 60 years. This presentation intends to provide an introductory overview on the thermal aging phenomena in LWR relevant conditions and discussion on the measurements of mechanical property degradation after accelerated and LWR relevant thermal aging treatments. First, the thermal aging effect on toughness is discussed in terms of the causes of embrittlement and influential parameters. Second, the talk will include a comprehensive discussion on the thermal aging effects in different CASS grades (i.e., CF3, CF3M, CF8, and CF8M), which will focus on the influence of alloying elements such as molybdenum and carbon. Third, approximate analysis on thermal reaction in CASS was carried out using Arrhenius equation to decide the effective temperature range for accelerated aging experiments to simulate 60 and 80 years of services in limited time frame. The results will provide valuable insights in the degree of thermal aging. Fourth, calculation on equilibrium precipitation was performed for model CASS alloys using the CALPHAD program, and the results will be used to describe the precipitation behaviors in association with the degradation in mechanical properties. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Impact of Synthesis and Aging on Titanium Carbide MXenes for Printed Microsystems

This work investigates the long-term electrical stability of Ti3C2Tx MXene Inks under accelerated aging conditions. Inks were synthesized from commercial MAX-Phase precursors, drop-cast onto custom PCB’s and monitored automated in-situ measurements. Samples aged at 85°C/85% RH, 85°C/0% RH and ambient conditions revealed distinct degradation trends. Wet aged inks showed rapid resistance increased while etched formulations exhibited long term stability. These findings highlight the influence of synthesis stage and environmental exposure on MXene Inks reliability, offering critical insights for printed MEMS and sensor applications. Ongoing measurements extend the aging timeline beyond prior studies, marking the longest evaluation under accelerated aging conditions to date.

Aging↗
DOE OSTI2018

A Comprehensive Review toward the State-of-the-Art in Failure and Lifetime Predictions of Power Electronic Devices

This paper discusses various types of failure mechanisms, precursor parameters, and accelerated aging- based procedures to estimate the remaining life of power electronic devices. Special attention has been given to summarize the different techniques typically used for measuring the junction temperature, because it plays a vital role during accelerated aging and condition monitoring. We reviewed more than 250 papers, and the references list 139 of them in order to explain and address the advantages and disadvantages of various techniques towards the reliability prognosis. Thus, this paper can be considered as an expedient reference to conduct future research on lifetime prediction of existing power electronic devices.

42 ENGINEERING↗
DOE OSTI2019

Deficiency in the DNA repair protein ERCC1 triggers a link between senescence and apoptosis in human fibroblasts and mouse skin

ERCC1 (excision repair cross complementing-group 1) is a mammalian endonuclease that incises the damaged strand of DNA during nucleotide excision repair and interstrand cross-link repair. Ercc 1-/Δ mice, carrying one null and one hypomorphic Ercc1 allele, have been widely used to study aging due to accelerated aging phenotypes in numerous organs and their shortened lifespan. Ercc1 -/Δ mice display combined features of human progeroid and cancer-prone syndromes. Although several studies report cellular senescence and apoptosis associated with the premature aging of Ercc1 -/Δ mice, the link between these two processes and their physiological relevance in the phenotypes of Ercc1 -/Δ mice are incompletely understood. Here, we show that ERCC1 depletion, both in cultured human fibroblasts and the skin of Ercc1-/Δ mice, initially induces cellular senescence and, importantly, increased expression of several SASP (senescence-associated secretory phenotype) factors. Cellular senescence induced by ERCC1 deficiency was dependent on activity of the p53 tumor-suppressor protein. In turn, TNFα secreted by senescent cells induced apoptosis, not only in neighboring ERCC1-deficient nonsenescent cells, but also cell autonomously in the senescent cells themselves. In addition, expression of the stem cell markers p63 and Lgr6 was significantly decreased in Ercc1 -/Δ mouse skin, where the apoptotic cells are localized, compared to age-matched wild-type skin, possibly due to the apoptosis of stem cells. These data suggest that ERCC1-depleted cells become susceptible to apoptosis via TNFα secreted from neighboring senescent cells. We speculate that parts of the premature aging phenotypes and shortened health- or lifespan may be due to stem cell depletion through apoptosis promoted by senescent cells.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRSDate not supplied

A Multi Targeted Dietary Supplement as a Potential Countermeasure for Prolonged, Deep Space Exploration

Deep space exploration, particularly to the Moon and Mars, are currently major goals of NASA and other international space agencies. Long-term space flight presents unique challenges to the human physiology from microgravity, social isolation, altered circadian rhythm and radiation. Oxidative stress has been implicated as a crucial factor in space environment induced injury. Elucidating these detrimental effects on the central nervous system and brain is a primary objective, as they may result in adverse changes in astronaut behavior, mood and performance of critical tasks. We were recently funded by HRP Human Factors Behavioral Performance (HFBP) Element to test the hypothesis that Galactic Cosmic Ray Simulation (GCRsim) Ionizing Radiation (IR), microgravity and social isolation combine synergistically to trigger an oxidative stress response that alters immune homeostasis, brain structure and function, and neurobehavioral and cognitive performance. This project will identify potential biomarkers for, and mechanisms underlying, structural and functional changes in the immune and nervous systems leading to behavioral/cognitive performance deficits, and its potential application to develop effective countermeasures to mitigate negative health effects of long duration space habitation. Countermeasures to offset neurological damaged and cognitive deficits are paramount for protecting astronauts during deep space transits, but many countermeasures have been found to be unsuitable in ground-based model studies. We have developed a multi targeted dietary supplement (MTDS) designed to simultaneously ameliorate oxidative stress, inflammatory processes, energetic shortfalls, and membrane and mitochondrial deterioration. Administration of this MTDS has improved cognition and longevity in age accelerated and normal aging mice. Specifically, the MTDS was found to prevent a decline in mitochondrial complex III activity and cell loss, as well as prevent an increase in protein carbonyls and mitochondrial 3-nitrotyrosine in the brain of these mice. Further, administration of the MTDS was also found to reduce bone marrow chromosomal aberrations, DNA damage, lymphocyte apoptosis after whole body exposure of 2 Gy γ radiation. Mice exposed to a high dose cranially (10 Gy) had decreased cognitive responses (seen as increased latency time to uncover buried food and decreased novel object recognition), increased plasma 8-OHdG levels, increased markers of cell stress in the brain, decreased hippocampal brain-derived neurotrophic factor (BDNF) protein and decreased plasma levels of cytokines, all of which were ameliorated with treatment of the MTDS. As we have shown the supplement is protective in models of cognitive damage similar space environment stressors, particularly increased oxidative stress, we propose it may be a suitable countermeasure for upcoming deep space exploration.

radiation↗
NASA NTRSDate not supplied

A MULTI TARGETED DIETARY SUPPLEMENT AS A POTENTIAL COUNTERMEASURE FOR DEEP SPACE EXPLORATION

Future deep space exploration to the Moon and Mars and beyond are currently major goals of NASA. Space flight presents unique challenges to the human physiology from the combined effects of microgravity, social isolation, altered circadian rhythm and radiation. Oxidative stress has been implicated as a crucial factor in space environment induced injury. Elucidating these detrimental effects on the central nervous system and brain is a primary objective, as they may result in adverse changes in astronaut behavior, mood and performance of critical tasks. We were recently funded by HRP Human Factors Behavioral Performance (HFBP) Element to test the hypothesis that Galactic Cosmic Ray Simulation (GCRsim) Ionizing Radiation (IR), microgravity and social isolation combine synergistically to trigger an oxidative stress response that alters immune homeostasis, brain structure and function, and neurobehavioral and cognitive performance. This project will identify potential biomarkers for, and mechanisms underlying, structural and functional changes in the immune and nervous systems leading to behavioral/cognitive performance deficits, and its potential application to develop effective countermeasures to mitigate negative health effects of long duration space habitation. Countermeasures to offset neurological damaged and cognitive deficits are paramount for protecting astronauts during deep space transits, but many countermeasures have been found to be unsuitable in ground-based model studies. We have developed a multi targeted dietary supplement (MTDS) designed to simultaneously ameliorate oxidative stress, inflammatory processes, energetic shortfalls, and membrane and mitochondrial deterioration. Administration of this MTDS has improved cognition and longevity in age accelerated and normal aging mice. Specifically, the MTDS was found to prevent a decline in mitochondrial complex III activity and cell loss, as well as prevent an increase in protein carbonyls and mitochondrial 3-nitrotyrosine in the brain of these mice. Further, administration of the MTDS was also found to reduce bone marrow chromosomal aberrations, DNA damage, lymphocyte apoptosis after whole body exposure of 2 Gy γ radiation. Mice exposed to a high dose cranially (10 Gy) had decreased cognitive responses (seen as increased latency time to uncover buried food and decreased novel object recognition), increased plasma 8-OHdG levels, increased markers of cell stress in the brain, decreased hippocampal brain-derived neurotrophic factor (BDNF) protein and decreased plasma levels of cytokines, all of which were ameliorated with treatment of the MTDS. As we have shown the supplement is protective in models of cognitive damage similar space environment stressors, particularly increased oxidative stress, we propose it may be a suitable countermeasure for upcoming deep space exploration.

Stephanie Puukila↗
DOE OSTI2023

Machine-Learning Assisted Identification of Battery Life Models

Predictive battery life models are commonly utilized to extrapolate degradation trends observed during accelerated aging tests for simulation of degradation in real-world applications. Thus, fitting accelerated aging data as accurately as possible and with low uncertainty is crucial for making believable projections of battery lifetime, but it is challenging to identify algebraic expressions that accurately fit multivariate degradation trends. A review of models published in literature reveal some common expressions for fitting calendar aging data, which is only dependent on temperature and state-of-charge, but no consistency across many models for fitting cycle aging data, indicating the need for a statistically rigorous data driven approach for developing empirical models. This talk will describe a machine-learning assisted method for identification of predictive battery life models utilizing bilevel optimization and symbolic regression. Bilevel optimization with cross-validation is used to statistically determine cell- and stress-dependent model parameters, while symbolic regression identifies both linear and multiplicative candidate expressions to predict stress-dependent degradation rates by selecting low-order subsets of features from a generated feature library. Because model expressions are identified empirically, it is crucial to ensure resulting models behave according to physical expectations, so the stability of models for interpolation or extrapolation is interrogated qualitatively through simulation and quantitatively through cross-validation and uncertainty quantification via bootstrap resampling. This model identification approach substantially improves upon models identified purely using expert judgement in terms of both accuracy and uncertainty. Model simulation and validation is then conducted by deriving a state-equation form of the predictive model, enabling simulation of battery aging under dynamic stresses. This enables validation of the predictive battery model on lab-based tests with varying conditions or on drive-cycle or application-cycle testing protocols. Parameter uncertainty can be carried forward into model simulation, giving lifetime estimates and confidence windows for cell- or system-level lifetime. The financial impact of battery model uncertainty can be estimated by incorporating uncertainty into a technoeconomic model.

battery↗
DOE OSTI2019

Polymer Aging/Characterization Core Capability Enhancement is Underway (Progress Summary)

Motivation: Accelerated aging of polymeric materials is needed to predict their long-term mechanical functionality. Two key metrics used to evaluate their performance are compression set and load retention. Currently, specimens are aged under compressive strain at four different temperatures (25, 40, 55, and 70°C) for 1-2 years, and compression set and load retention are measured at various timepoints. At each timepoint, specimens are measured at three different relaxation times (immediately, 1 hr, and 24 hrs) after removal from the aging fixtures. The measurements include both thickness measurement and load testing. Time-temperature superposition (TTS) is applied to the isothermal data to obtain long-term predictions. There is a desire to reduce both the length of the studies and the amount of effort required to perform the studies. Significance: Additional aging ovens will provide the opportunity to add a higher fifth temperature, which could reduce the length of accelerated aging studies, as well as provide a spare oven in case one fails. If determined to be feasible, instrumented aging fixtures could reduce the amount of effort required to perform the studies, potentially eliminating the need to remove the specimens from the fixtures. Progress: Two new aging ovens have been received. The controllers were verified to be operational. The nitrogen purge still needs to be verified. Instrumented aging fixtures potentially including gap adjustment (to set the aging strain and measure specimen thickness) and a load transducer are under consideration.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Cu/Al Through Au Diffusion Characterized by KPFM

The nanometer scale characterization technique of Frequency Modulated Kelvin Probe Force Microscopy (FM-KPFM) will be used to assess a diffusion study on thin metal films that undergo accelerated aging. The KPFM technique provides a relatively easy, non-destructive methodology that does not require high-vacuum facilities to obtain nanometer-scale spatial resolution of surface chemistry changes. The KPFM technique will be exercised in an effort to explore its capacity to map surface potential contrast caused by diffusion in a manner that allows for a qualitative assessment of diffusion of Cu or Al through Au. Supporting data will be obtained from traditional techniques: AES, XPS and UPS. An aging study was conducted on thin metal test specimens comprised of 500nm Cu or Al then 500nm Au on Si. The accelerated aging process was performed under inert conditions at aging temperatures of 100°C for Cu/Au film stack and 175°C for Al/Au film stack at aging times of 8 hours, 24 hours, 96 hours (4 days), and 216 hours (9 days).A calibration method was developed using Au, Al and Cu standards to establish precision and repeatability of the KPFM technique. The average Contact Potential Difference (CPD)s and standard deviations for each metal were found and summarized. Averages from surface roughness of the AFM topography images and roughness analysis of KPFM potential images which yield an average CPD of each area of unaged vs aged coupon surfaces were compared and show trends that indicate surface chemistry.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Fiberboard Properties and Degradation Rates for Storage of 9975 Shipping Packages in KAC (2021 Status Report)

Thermal, mechanical, and physical properties have been measured on fiberboard samples following accelerated aging for up to 16 years. The aging environments include elevated temperature up to 250 ºF (the maximum allowed service temperature for fiberboard in 9975 packages) and elevated humidity. Accelerated aging results have been analyzed and used to build aging models. Correlations relating several properties (thermal conductivity, energy absorption, weight, dimensions, and density) to their rate of change in potential storage environments have been developed. Combined with an estimate of the actual conditions the fiberboard experiences in K-Area Complex (KAC), these models allow development of service life predictions. KAC completed calculations that supported extending the service life of 9975 packages with 3013 and non3013 containers in storage from 15 years to 20 years. These calculations addressed the potential for degraded fiberboard properties following 20 years in storage using degradation models developed previously. The updated degradation models developed in this report have been compared to the assumptions in these calculations, and the current results for fiberboard dimensions, density, radial thermal conductivity, and energy absorption remain consistent with those calculations. The axial thermal conductivity degradation rate slightly exceeds calculations estimate of 0.5% per year between 130 and 160 °F. Additional data will continue to be collected to permit future refinements to the models and assumptions. Some of the predicted degradation rates presented in this report are extreme. However, these relate to environments that do not exist within KAC or would be postulated only as upset conditions that would not likely persist for an extended period. For a typical package stored in KAC with approximately 10-12 watts internal heat load or less, and ambient temperatures below 90 ºF, the fiberboard assemblies experience storage conditions less severe than any of the aging environments. Fiberboard in conforming packages with lower internal heat loads should experience little or no degradation and is expected to provide a service life beyond the currently approved 20 year storage period. Packages with higher internal heat loads may not continue to perform their required safety functions beyond 20 years. Ultimately, service life will be determined by the cumulative effect of degradation from all the conditions these packages might encounter. The results and model predictions presented in this report are applicable to 9975 packages with cane or softwood fiberboard overpack assemblies. These degradation models do not address the effects of nonconforming conditions such as the presence of excess moisture and mold or beetle infestations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Fiberboard Properties and Degradation Rates for Storage of 9975 Shipping Package in KAC (2022 Status Report)

Thermal, mechanical, and physical properties have been measured on fiberboard samples following accelerated aging for up to 17 years. The aging environments include elevated temperature up to 250 °F (the maximum allowed service temperature for fiberboard in 9975 packages) and elevated humidity. Accelerated aging results have been analyzed and used to build aging models. Correlations relating several properties (thermal conductivity, energy absorption, weight, dimensions, and density) to their rate of change in potential storage environments have been developed. Combined with an estimate of the actual conditions the fiberboard experiences in K-Area Complex (KAC), these models allow development of service life predictions. KAC completed calculations that supported extending the service life of 9975 packages with 3013 containers in storage from 20 years to 40 years. These calculations addressed the potential for degraded fiberboard properties following 40 years in storage using degradation models developed previously. Due to differences in containers, 9975 packages with non-3013 containers are only approved for 20 years of storage. The updated degradation models developed in this report have been compared to the assumptions in those calculations, and the current results for fiberboard dimensions, density, radial thermal conductivity, and energy absorption remain consistent with those calculations. The axial thermal conductivity degradation rate slightly exceeds calculations estimate of 0.5% per year between 130 and 160 °F. Additional data will continue to be collected to permit future refinements to the models and assumptions. Some of the predicted degradation rates presented in this report are extreme. However, these relate to environments that do not exist within KAC or would be postulated only as upset conditions that would not likely persist for an extended period. For a typical package stored in KAC with approximately 10-12 watts internal heat load or less, and ambient temperatures below 90 °F, the fiberboard assemblies experience storage conditions less severe than any of the aging environments. Fiberboard in conforming packages with lower internal heat loads should experience little or no degradation and is expected to provide a service life beyond the currently approved 40 year storage period. Packages with higher internal heat loads may not continue to perform their required safety functions beyond 40 years. Ultimately, service life will be determined by the cumulative effect of degradation from all the conditions these packages might encounter. The results and model predictions presented in this report are applicable to 9975 packages with cane or softwood fiberboard overpack assemblies. These degradation models do not address the effects of non-conforming conditions such as the presence of excess moisture and mold or beetle infestations.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Materials Compatibility in High Test Hydrogen Peroxide

Previous ratings of the compatibility of high test hydrogen peroxide (HTP) with materials are not adequate for current needs. The goal of this work was to develop a new scheme of evaluation of compatibility of HTP with various materials. Procedures were developed to enrich commercially available hydrogen peroxide to 90% concentration and to assay the product. Reactivity testing, accelerated aging of materials and calorimetry studies were done on HTP with representative metallic and non-metallic materials. It was found that accelerated aging followed by concentration determination using refractive index effectively discriminated between different Class 2 metallic materials. Preliminary experiments using Differential Scanning Calorimetry (DSC) suggest that a calorimetry experiment is the most sensitive means to assay the compatibility of HTP with materials.

Gostowski, Rudy↗
DOE OSTI2018

Grain Boundary Diffusion Characterized by KPFM

The nanometer scale characterization technique of Frequency Modulated Kelvin Probe Force Microscopy (FM-KPFM) will be used to assess a preliminary diffusion study on thin metal films that undergo accelerated aging. The KPFM technique provides a relatively easy, non-destructive methodology that does not require high-vacuum facilities to obtain nanometer spatial resolution of surface chemistry changes and will be exercised in an effort to explore its capacity to map surface potential contrast caused by Cu diffusion in a manner that allows for a qualitative assessment of diffusion rate kinetics. Supporting data will be obtained from traditional techniques: AES, XPS and UPS. An aging study was conducted on thin metal test specimens comprised of Ti or Cr/Cu/Au layer thicknesses of 50nm/500nm/500nm up to 4μm respectively. The accelerated aging process, was performed in air at aging temperatures of 60°C, 100°C, and 125°C for aging times of 8 hours, 24 hours, 96 hours (4 days), and 216 hours (9 days). A calibration method was developed using Au, Al and Ni standards to establish precision and repeatability of the KPFM technique. Average CPDs and standard deviations for each metal were found and summarized.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Thermal Battery Degradation Mechanisms

Diffuse reflectance IR spectroscopy (DRIFTS) was used to investigate the effect of accelerated aging on LiSi based anodes in simulated MC3816 batteries. DRIFTS spectra showed that the oxygen, carbonate, hydroxide and sulfur content of the anodes changes with aging times and temperatures, but not in a monotonic fashion that could be correlated to phase evolution. Bands associated with sulfur species were only observed in anodes taken from batteries aged in wet environments, providing further evidence for a reaction pathway facilitated by H 2 S transport from the cathode, through the separator, to the anode. Loss of battery capacity with accelerated aging in wet environments was correlated to loss of FeS 2 in the catholyte pellets, suggesting that the major contribution to battery performance degradation results from loss of active cathode material.

25 ENERGY STORAGE↗
NASA NTRS1982

Experimental evaluation of the Battelle accelerated test design for the solar array at Mead, Nebraska

A previously developed test design for accelerated aging of photovoltaic modules was experimentally evaluated. The studies included a review of relevant field experience, environmental chamber cycling of full size modules, and electrical and physical evaluation of the effects of accelerated aging during and after the tests. The test results indicated that thermally induced fatigue of the interconnects was the primary mode of module failure as measured by normalized power output. No chemical change in the silicone encapsulant was detectable after 360 test cycles.

Frickland, P. O.↗
DOE OSTI2012

Monitoring Thermal Fatigue Damage In Nuclear Power Plant Materials Using Acoustic Emission

Proactive aging management of nuclear power plant passive components requires technologies to enable monitoring and accurate quantification of material condition at early stages of degradation (i.e., pre-macrocrack). Acoustic emission (AE) is well-suited to continuous monitoring of component degradation and is proposed as a method to monitor degradation during accelerated thermal fatigue tests. A key consideration is the ability to separate degradation responses from external sources such as water spray induced during thermal fatigue testing. Water spray provides a significant background of acoustic signals, which can overwhelm AE signals caused by degradation. Analysis of AE signal frequency and energy is proposed in this work as a means for separating degradation signals from background sources. Encouraging results were obtained by applying both frequency and energy filters to preliminary data. The analysis of signals filtered using frequency and energy provides signatures exhibiting several characteristics that are consistent with degradation accumulation in materials. Future work is planned to enable verification of the efficacy of AE for thermal fatigue crack initiation detection. While the emphasis has been placed on the use of AE for crack initiation detection during accelerated aging tests, this work also has implications with respect to the use of AE as a primary tool for early degradation monitoring in nuclear power plant materials. The development of NDE tools for characterization of aging in materials can also benefit from the use of a technology such as AE which can continuously monitor and detect crack initiation during accelerated aging tests.

acoustic emission↗
DOE OSTI2024

Microstructural Coarsening Kinetics and Mechanical Property Changes in Long-Term Aged Sn–Pb–Sb Solder Joints

Tin-lead-antimony (50Sn–47Pb–3Sb wt.%) soldered assemblies were mechanically tested approximately 30 years after initial production and found to have solder joints of reduced strength. The microstructure of this solder alloy exhibits a ternary eutectic structure with Sn-rich, Pb-rich, and SnSb phases. Accelerated aging was performed to evaluate solder microstructural coarsening and associated strength of laboratory solder joints to correlate these properties to the “naturally aged” solder joints. Isothermal aging was conducted at room temperature, 55, 70, 100, and 135 °C and aging times that ranged from 0.1 to 365 days. The coarsening kinetics of the Pb-rich phase were determined through optical microscopy and image analysis methods established in previous studies on binary Sn–Pb solder. A kinetic equation was developed with time exponent n of 0.43 and activation energy of 24000 J/mol, suggesting grain boundary diffusion or other fast diffusion pathways controlling the microstructural evolution. Compression testing and Vickers microhardness showed significant strength loss within the first 20–30 days after soldering; then, the microstructure and mechanical properties changed more slowly over long periods of time. Further, by combining accelerated aging data and the microstructure-based kinetics, strength predictions were made that match well with the properties of the actual soldered assemblies naturally aged for 30 years. However, aging at the highest temperature of 135 °C produced anomalous behavior suggesting that extraneous aging mechanisms are active. Therefore, data obtained at this temperature or higher should not be used. Overall, the combined microstructural and mechanical property methods used in this study confirmed that the observed reduction in strength of ~ 30-year-old solder joints can be accounted for by the microstructural coarsening that takes place during long-term solid-state aging.

36 MATERIALS SCIENCE↗