Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “THERMAL STRESS”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,747 records · Page 97
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Extend an innovative HPC-Compatible Multiple Temporal-spatial Resolution Concurrent Finite Element Modeling Approach to Guide Laser Powder Bed Fusion Additive

Laser power bed fusing (PBF) additive manufacturing is a key enabling technology to manufacture highly complex and integrated automotive structures. However, the geometric complexity of PBF-AM technique also leads to highly non-uniform heating and cooling rate in the manufactured part, which may cause flaw formation and produce excessive and nonuniform residual stresses, which increase quality uncertainties and manufacture issues, leading to increases in cost and energy consumption in the form of rejected parts. In this research project, we developed an innovative Multi-Spatial-Temporal-Resolution Finite Element (MUST-FE) method and completed the corresponding high performance computation (HPC) platform-based in-house code, which enables high accuracy prediction of temperature and residual stress fields for component-scale PBF-AM manufacture in efficient computation time. The MUST-FE model is calibrated and validated with a “2D pad” AlSi10Mg experiments by matching the melt pool shape and dimension, and with a “XY-cross” AlSi10Mg experiment by matching the thermal distortion and residual stress. The innovative multi-resolution and concurrent modeling approach adopted in this code ensures accuracy and computational efficiency, which will enable energy-efficient and high-yield, low-cost manufacturing of optimized, qualifiable automotive structures and contribute towards reaching technical targets outlined in AMO’s Program Plan to develop additive manufacturing systems that deliver consistently reliable parts with predictable properties.

36 MATERIALS SCIENCE↗
NASA NTRS1979

An experimental and analytical investigation of the rail shear-test method as applied to composite materials

This report presents the results from an experimental and analytical investigation of the stress distributions occurring in a rail shear test. The effects of non-uniform stresses induced by differential thermal expansion, rail flexibility and specimen aspect ratio on measured shear modulus and ultimate strength of composite laminates are shown. A two-dimensional linearly elastic finite element model was used to analytically determine how various geometric parameters influenced the magnitude and distribution of inplane normal and shear stresses in a tensile rail shear specimen. Rail shear tests were conducted at room temperature and 589 K (600 F) on selected graphite-polyimide composite laminates using two titanium rail configurations. The analysis and test methods are discussed, and the results of the effects of the various parameters on shear modulus and ultimate strength are presented.

Garcia, R.↗
NASA NTRS2015

Methodology for Producing a Uniform Distribution of UO2 in a Tungsten Matrix

Current work at NASA's Marshall Space Flight Center (MSFC) is focused on the development CERMET fuel materials for Nuclear Thermal Propulsion (NTP). The CERMETs consist of uranium dioxide (UO2) fuel particles embedded in a tungsten (W) metal matrix. Initial testing of W-UO2 samples fabricated from fine angular powders performed reasonably well, but suffered from significant fuel loss during repeated thermal cycling due to agglomeration of the UO2 (1). The blended powder mixtures resulted in a non-uniform dispersion of the UO2 particles in the tungsten matrix, which allows rapid vaporization of the interconnected UO2 from the sample edges into the bulk material. Also, the angular powders create areas of stress concentrations due to thermal expansion mismatch, which eventually cracks the tungsten matrix. Evenly coating spherical UO2 particles with chemical vapor deposited (CVD) tungsten prior to consolidation was previously demonstrated to provide improved performance. However, the CVD processing technology is expensive and not currently available. In order to reduce cost and enhance performance, a powder coating process has been developed at MSFC to produce a uniform distribution of the spherical UO2 particles in a tungsten matrix. The method involves utilization of a polyethylene binder during mixing which leads to fine tungsten powders clinging to the larger UO2 spherical particles. This process was developed using HfO2 as a surrogate for UO2. Enough powder was mixed to make 8 discs (2cm diameter x 8mm thickness) using spark plasma sintering. A uniaxial pressure of 50 MPa was used at four different temperatures (2 samples at each temperature). The first two samples were heated to 1400C and 1500C respectively for 5 minutes. Densities for these samples were less than 85% of theoretical, so the time at temperature was increased to 20 minutes for the remaining samples. The highest densities were achieved for the two samples sintered at 1700C (approx. 92% of theoretical). Scanning electron microscopy (SEM) of the mixed powders and the sintered samples along with energy dispersive x-ray analysis was obtained. The SEM of the powders clearly show the fine W powder adhered to the larger HfO2 particles and a uniform distribution of HfO2 particles in a tungsten matrix upon densification. Vicker's Microhardness testing was also performed on all samples using 0.5, 1.0 and 2.0 kg loads. Five indents were made at each load level. All indents were placed in the tungsten matrix to assist as a proxy in measuring densification. The highest hardness value was obtained for the 1700C specimens. The hardness average for these samples was 312.14 MPa. This powder processing method has been applied to W/UO2 powders with the SEM of the powders appearing similar to the W/HfO2 powder images.

Tucker, Dennis S.↗
NASA NTRS2001

Finite Element Analysis of Active and Sensory Thermopiezoelectric Composite Materials

Analytical formulations are developed to account for the coupled mechanical, electrical, and thermal response of piezoelectric composite materials. The coupled response is captured at the material level through the thermopiezoelectric constitutive equations and leads to the inherent capability to model both the sensory and active responses of piezoelectric materials. A layerwise laminate theory is incorporated to provide more accurate analysis of the displacements, strains, stresses, electric fields, and thermal fields through-the-thickness. Thermal effects which arise from coefficient of thermal expansion mismatch, pyroelectric effects, and temperature dependent material properties are explicitly accounted for in the formulation. Corresponding finite element formulations are developed for piezoelectric beam, plate, and shell elements to provide a more generalized capability for the analysis of arbitrary piezoelectric composite structures. The accuracy of the current formulation is verified with comparisons from published experimental data and other analytical models. Additional numerical studies are also conducted to demonstrate additional capabilities of the formulation to represent the sensory and active behaviors. A future plan of experimental studies is provided to characterize the high temperature dynamic response of piezoelectric composite materials.

Lee, Ho-Jun↗
NASA NTRS1988

A study on the thermal and moisture influences on the free-edge delamination of laminated composites

A simple delamination analysis method is presented here. It is based on a shear-type deformation theory and includes hygrothermal effects. These environmental conditions are applied to the strain energy release rate and interlaminar shear stresses. The method is applied to mixed mode edge delamination specimens made of T300/5208 graphite/epoxy material. Residual thermal and moisture stresses significantly influenced the strain energy release rate and interlaminar stresses. Both experienced large increases when thermal conditions were added to the mechanical strains. These effects were alleviated when moisture stresses were included. Thermal effects on the interlaminar shear stress and total energy release rate were totally alleviated for the same specific moisture content. Moreover, the value of the moisture content was not significantly affected by the stacking sequence for the laminates considered.

Mahler, Mary A.↗
DOE OSTI2025

The genome of the polyextremophilic yeast, Naganishia friedmannii, reveals adaptations involved in stress response pathways, carbohydrate metabolism expansion, and a limited DNA repair repertoire

Here we report the draft genome sequence of Naganishia friedmannii (formerly Cryptococcus friedmannii) isolate, a Basidiomycota yeast commonly found in some of the most extreme environments of the Earth's cryosphere. We isolated N. friedmannii strain Llullensis from soils at 6000 m above sea level on Volcán Llullaillaco, Argentina. The genome was 22.2 Mb with 6251 identified protein coding genes. Proteins known to be associated with thermal, osmotic, and radiation stress were identified in the genome. Comparative analysis with seven other Naganishia genomes revealed unique features underlying its polyextremophilic lifestyle. Naganishia friedmannii showed an expansion of genes involved in breaking down plant-derived carbohydrates, supporting the hypothesis that it survives at high elevations by metabolizing wind-deposited organic matter. Surprisingly, many genes involved in cell-cycle checkpoints and DNA repair were missing, as in several other Naganishia species. This extensive loss may be adaptive in extreme environments prone to abiotic stress, where a high mutation rate could generate advantageous traits, and reduced cell-cycle control may allow for faster reproduction that would be advantageous for rapid growth during brief periods of soil wetting following rare snow events.

Vimercati, Lara↗
NASA NTRS1971

Factors affecting the thermal shock behavior of yttria stabilized hafnia based graphite and tungsten composites.

Hafnia-based composites containing either graphite or tungsten were investigated as rocket nozzle throat inserts in solid propellant rocket engines. The thermal shock resistance of these materials is considered in terms of macroscopic thermal conductivity, thermal expansion, modulus of elasticity, and compressive fracture stress. The effect of degree of hafnia stabilization, density, and graphite or tungsten content upon these parameters is discussed. The variation of the ratio of elastic modulus to compressive fracture stress with density and its effect upon thermal shock resistance of these materials are discussed in detail.

Lineback, L. D.↗
NASA NTRS1984

Thermal and thermomechanical effects in dry sliding

Developments in the study of interrelated thermal and mechanical phenomena in sliding systems are reviewed. The topics reviewed include mechanisms of frictional heating and the distribution of heat during sliding friction, the experimental measurement and analysis of surface and near-surface temperatures resulting from frictional heating, thermal deformation around sliding contacts and the changes in contact geometry caused by thermal deformation and thermoelastic instability, and the thermomechanical stress distribution around the frictionally heated and thermally deformed contact spots. The influence of the thermal and thermomechanical contact phenomena on friction and wear, surface melting, softening, chemical deterioration, and thermocracking are discussed. The phenomena have important implications in the design and application of sliding or sliding-rolling mechanical components such as dynamic seals, brakes, clutches, plastic bearings, solid or boundary-lubricated bearings, and gears.

Kennedy, F. E., Jr.↗
NASA NTRS1993

Interface considerations in Al2O3/NiAl composite

The fiber-matrix interface requirements in an Al2O3/NiAl composite were examined from theoretical considerations. Several factors that influence the interface bonding requirements were analyzed. These include: (1) residual stresses due to fiber-matrix coefficient of thermal expansion (CTE) mismatch; (2) matrix cracking stress at room temperature; (3) fracture toughness at room temperature; (4) load transfer from the matrix to the fiber and ultimate tensile strength at the use temperature; and (5) creep resistance at high temperature. A relatively weak fiber-matrix bond, with an interfacial shear strength of approximately 15-20 MPa, might be sufficient for attaining the desired mechanical properties in the fiber direction at the use temperature. A weak fiber-matrix bond is also beneficial for increasing the fracture toughness of the composite at room temperature. In contrast, a strong fiber-matrix bond is required to withstand some of the residual stresses resulting from the fiber-matrix CTE mismatch, which are not likely to be reduced significantly by interface coatings. A relatively strong bond is also beneficial in increasing the matrix cracking stress at room temperature. Various interface coating options to accommodate the conflicting bonding requirements were reviewed. One viable coating option is to incorporate a thick, ductile interface layer well bonded to both the fiber and the matrix.

Misra, Ajay K.↗
NASA NTRS2004

Fluid Structure Interaction in a Turbine Blade

An unsteady, three dimensional Navier-Stokes solution in rotating frame formulation for turbomachinery applications is presented. Casting the governing equations in a rotating frame enabled the freezing of grid motion and resulted in substantial savings in computer time. The turbine blade was computationally simulated and probabilistically evaluated in view of several uncertainties in the aerodynamic, structural, material and thermal variables that govern the turbine blade. The interconnection between the computational fluid dynamics code and finite element structural analysis code was necessary to couple the thermal profiles with the structural design. The stresses and their variations were evaluated at critical points on the Turbine blade. Cumulative distribution functions and sensitivity factors were computed for stress responses due to aerodynamic, geometric, mechanical and thermal random variables.

Gorla, Rama S. R.↗
DOE OSTI2021

Experimental Fabrication of Porous Additive Manufactured Material

Nuclear industries can benefit from materials that can perform well mechanically and thermally in high temperature and corrosion environments. Functionally graded materials (FGM) are materials manufactured with complex spatial, structural, and chemical compositions, creating components predesigned with tailored microstructural and mechanical properties. Porosity-graded FGMs are designed to introduce pores into a component’s structure as a mechanism to increase bulk or surface material performance, such as stress accommodation and negative thermal conductivity. Additive manufacturing (AM) techniques such as laser energy net shape (LENS) and wire arc additive manufacturing (WAAM), excel in high energy density, point-to-point metal deposition, and present in combination with other combinatorial approaches, exciting methods to manufacture porous FGM components. This project is also examining plasma jet printing as another means for method evaluations for smaller scale graded components. This study explores AM FGM process parameters and combinatorial fabrication methodologies for stainless steel components functionally graded in porosity levels. Preliminary characterization results are provided to attest the feasibility of the combinational fabrication techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Prediction of continuous porosity gradients in ceramics using ZnO as a model material

Materials with gradient microstructures have a wide range of applications such as cutting tools, armor, and electronic devices. However, it is difficult to predict and control the gradient microstructure during processing. In the present work, a continuous porosity gradient was successfully achieved in ZnO material via spark plasma sintering with a large induced thermal gradient. The porosity is overestimated if isothermal prediction is applied. The current work proposed a more accurate prediction of the porosity by considering the stress-shielding effect caused by the thermal gradient. The shielding effect results from different stress states in the sample due to differential sintering: the hotter side of the specimen experiences a higher strain rate and more shrinkage while the colder side experiences a lower strain rate and less shrinkage simultaneously. Therefore, the axial strains are varied throughout the sample thickness. Using the constituent equations in advanced sintering analysis, the shield stress was calculated to be approximately 13 MPa for the viscoelastic assumption of sintering. To improve the accuracy of predicting porosity gradient, it is necessary to add a load to overcome the shield stress when the materials are sintered with a thermal gradient.

36 MATERIALS SCIENCE↗
NASA NTRS1978

The role of thermal shock in cyclic oxidation

The effect of thermal shock on the spalling of oxides from the surfaces of several commercial alloys was determined. The average cooling rate was varied from approximately 240 C per second to less than 1.0 C per second during cyclic oxidation tests in air. The tests consisted of one hundred cycles of one hour at the maximum temperature (1100 or 1200 C). The alloys were HOS-875, TD-Ni, TD-NiCrAl, IN-601, IN-702, and B-1900 plus Hf. All of these alloys exhibited partial spalling within the oxide rather than total oxide loss down to bare metal. Thermal shock resulted in deformation of the metal which in turn resulted, in most cases, in changing the oxide failure mode from compressive to tensile. Tensile failures were characterized by cracking of the oxide and little loss, while compressive failures were characterized by explosive loss of platelets of oxide. This behavior was confirmed by examination of mechanically stressed oxide scales. The thermally shocked oxides spalled less than the slow cooled samples with the exception of TD-NiCrAl. This material failed in a brittle manner rather than by plastic deformation.

Lowell, C. E.↗
DOE OSTI2021

Aging and Lifetimes Milestone 7777, G.C. #4: Assess the ability of MRI to identify chemical and mechanical heterogeneity in polymers at various length scales

Polysiloxane foams utilized for stockpile applications experience changes over time induced by exposure to thermal, radiative, and mechanical stresses. The interplay of these stresses can lead to chemical and/or physical changes in the polymer, such as compression set and material degradation over time. Understanding the mechanisms of material aging and identifying material degradation prior to failure are critical in maintaining the integrity of the nuclear stockpile. Our prior work using solid-state NMR spectroscopy has shown that we can observe signatures of thermal, radiative, and mechanical aging of silicone elastomers using differences in NMR parameters such as relaxation (T1 and T2). However, most of our measurements have been on bulk samples and have only provided an average aging behavior of each sample. Here, we have used magnetic resonance imaging (MRI) to provide relaxation-weighted images that are a metric of structural heterogeneity (cross-link density) in polymers across multiple length scales. In addition, the larger sample size that can be accommodated in animal MRI scanners has the potential to make the technique adaptable to detecting heterogeneities whole parts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

LLNL FY22 Aging and Lifetimes Exit Criteria: Milestone 8119, GC#01

Polysiloxane foams utilized for stockpile applications experience changes over time induced by exposure to thermal, radiative, and mechanical stresses. The interplay of these stresses can lead to chemical and/or physical changes in the polymer, such as compression set and material degradation over time. Understanding the mechanisms of material aging and identifying material degradation prior to failure are critical in maintaining the integrity of the nuclear stockpile. Our prior work using solid-state NMR spectroscopy has shown that we can observe signatures of thermal, radiative, and mechanical aging of silicone elastomers using differences in NMR parameters such as relaxation (T1 and T2). However, most of our measurements have been on bulk samples and have only provided an average aging behavior of each sample. Here, we have used magnetic resonance imaging (MRI) to provide relaxation-weighted images that are a metric of structural heterogeneity (crosslink density) in polymers across multiple length scales. In addition, the larger sample size that can be accommodated in animal MRI scanners has the potential to make the technique adaptable to detecting heterogeneities in whole parts.

36 MATERIALS SCIENCE↗
NASA NTRS2015

Actuators Using Piezoelectric Stacks and Displacement Enhancers

Actuators are used to drive all active mechanisms including machines, robots, and manipulators to name a few. The actuators are responsible for moving, manipulating, displacing, pushing and executing any action that is needed by the mechanism. There are many types and principles of actuation that are responsible for these movements ranging from electromagnetic, electroactive, thermo-mechanic, piezoelectric, electrostrictive etc. Actuators are readily available from commercial producers but there is a great need for reducing their size, increasing their efficiency and reducing their weight. Studies at JPL’s Non Destructive Evaluation and Advanced Actuators (NDEAA) Laboratory have been focused on the use of piezoelectric stacks and novel designs taking advantage of piezoelectric’s potential to provide high torque/force density actuation and high electromechanical conversion efficiency. The actuators/motors that have been developed and reviewed in this paper are operated by various horn configurations as well as the use of pre-stress flexures that make them thermally stable and increases their coupling efficiency. The use of monolithic designs that pre-stress the piezoelectric stack eliminates the use of compression stress bolt. These designs enable the embedding of developed solid-state motors/actuators in any structure with the only macroscopically moving parts are the rotor or the linear translator. Finite element modeling and design tools were used to determine the requirements and operation parameters and the results were used to simulate, design and fabricate novel actuators/motors. The developed actuators and performance will be described and discussed in this paper.

rotary devices↗
NASA NTRSDate not supplied

Thermal Performance of Perovskite-Based Photovoltaics for Operation in Low Earth Orbit

Perovskite-based photovoltaics are attractive for applications in space. The space environment is harsh with extreme temperatures, atomic oxygen, ionizing radiation, UV radiation, and thermal cycling. Here, we evaluate the thermal performance of a perovskite active layer and perovskite photovoltaic devices in low earth orbit. We determine that a 1 µm layer of silicon oxide coupled with a 500 nm zirconia thin film aid in cell thermal management. We model the residual stresses between various layers in the device and prove that thermally induced mechanical failure of the perovskite (t > 460 years) is unlikely during the operating lifetime of a space mission. We identify target power conversion efficiencies to manage operating temperature of a perovskite-based photovoltaic.

Timothy S. Krause↗
DOE OSTI2025

Bayesian Calibration of Nuclear Graphite Property Models Accounting for Model Inadequacy and Impacts on Component Performance

Nuclear-grade structural graphite is extensively utilized in the core designs of various advanced nuclear reactors. In the reactor environment, graphite is subjected to prolonged exposure to extreme conditions, including high temperatures, radiation, and potentially molten salt and oxygen. Such exposure can induce several degradation mechanisms in graphite, including nonuniform volumetric strains caused by irradiation and thermal expansion, leading to stresses that may compromise the performance of graphite components. Assessing component integrity requires accurate models of graphite's thermomechanical response. This report documents the Bayesian calibration of thermomechanical properties for nuclear-grade graphite and their application to graphite component modeling and simulation using the Grizzly code. As part of this work, uncertainty-quantified models were developed for the elastic modulus, coefficient of thermal expansion, irradiation-induced dimensional change, and irradiation-induced creep for graphite grades IG-110, NBG-18, NBG-17, PCEA, and 2114. Using a hierarchical Bayesian approach, multiple experimental data sources were combined to develop Gaussian process models for the properties. Using the Kennedy O'Hagan framework, the uncertainties due to inadequacies in the model and the inherent spread in the experimental data were quantified for three different models. These uncertainty-quantified models, with a model-form correction, were subsequently applied to a coupled-physics simulation of representative graphite components, revealing that the uncertainties have a large impact on the components' deformation.

36 - MATERIALS SCIENCE↗