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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Scale effects on the transverse tensile strength of graphite epoxy composites

The influence of material volume on the transverse tensile strength of AS4/3501-6 graphite epoxy composites was investigated. Tensile tests of 90 degree laminates with 3 different widths and 5 different thicknesses were conducted. A finite element analysis was performed to determine the influence of the grip on the stress distribution in the coupons and explain the tendency for the distribution of failure locations to be skewed toward the grip. Specimens were instrumented with strain gages and extensometers to insure good alignment and to measure failure strains. Data indicated that matrix dominated strength properties varied with the volume of material that was stressed, with the strength decreasing as volume increased. Transverse strength data were used in a volumetric scaling law based on Weibull statistics to predict the strength of 90 degree laminates loaded in three point bending. Comparisons were also made between transverse strength measurements and out-of-plane interlaminar tensile strength measurements from curved beam bending tests. The significance of observed scale effects on the use of tests for material screening, quality assurance, and design allowables is discussed.

Obrien, T. Kevin↗
DOE OSTI2018

Effect of graphite morphology on the tensile strength and thermal conductivity of cast iron

Highlights: • The graphite morphology is characterized from 3D structure using X–ray tomography. • The size, distribution, shape and interconnectivity of graphite are estimated. • The influences of graphite morphology on tensile properties and thermal conductivity are evaluated. • The mechanism of tensile strength and the model of thermal conductivity are discussed. - Abstract: Graphite morphology is a very important parameter affecting the properties of cast iron. In this study, the graphite morphology was characterized using both 3D and 2D structures. The experimental results revealed that when the graphite was less spheroidal, the graphite had greater interconnectivity in the 3D structure of the cast iron. The size, distribution, volume fraction, and shape of the graphite were estimated. Moreover, the influences of the graphite's morphology, size, and distribution on the tensile property and thermal conductivity at different temperatures were estimated. The experimental results revealed that with an increase in temperature, the thermal conductivity initially increased, and then decreased, whereas the tensile strength decreased slightly at first, and then decreased rapidly. In addition, with an increase in the percentage of compacted graphite, the tensile strength decreased and the thermal conductivity increased. The fracture surfaces of tensile specimens were also estimated. Finally, the mechanism of tensile strength and the model of thermal conductivity were investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of Sample Thickness on the Tensile Strength of Small Graphite Discs

This report formally documents the completion of the Advanced Reactor Technologies (ART) Level 3 Milestone (M3TG-24OR0501054), “Continue activities related to Split Disc-DIC - complete analysis of effect of sample thickness on one fine grain graphite,” due May 31, 2024. Details within this report outline the status of activities aimed at elucidating the effect of sample thickness on the tensile strength measurement using the small-disc, split-disc testing standard in support of the US Department of Energy’s ART Graphite R&D Program. The ASTM D8289, Standard Test Method for Tensile Strength Estimate by Disc Compression of Manufactured Graphite, was developed to provide an alternative means for testing tensile strength on smaller specimens, which are compatible with available irradiation capsule volumes, and other compatibility measurements. ASTM D8289 specifies that acceptable specimen diameter can range from 6 to 12.7 mm and that the maximum allowed sample thickness should be half of the diameter. However, information is limited with respect to the effect of thickness on the measured splitting tensile strength. This report documents efforts to understand the effect of sample thickness on splitting tensile strength. The work involved testing Ø12.7 mm samples of fine-grain graphites 2114 and IG-110 of different thicknesses (6.35, 5, 4, and 3 mm). The digital image correlation (DIC) method was applied to the samples, along with the ASTM D8289 Standard, to help interpret the measured results.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Filament-wound graphite/epoxy rocket motor case

The fabrication procedures are described for a filament-wound rocket motor case, approximately 56 cm long x 71 cm diameter, utilizing high tensile strength graphite fibers. The process utilized Fiberite Hy-E-1330B prepreg tape which consists of Courtaulds HTS fibers in a temperature-sensitive epoxy matrix. This fabrication effort, with resultant design, material and process recommendations, substantiates the manufacturing feasibility of graphite/epoxy rocket motor cases in the 56 cm x 71 cm size range.

Humphrey, W. D.↗
DOE OSTI2020

Mersen Grade 2114: A Comparison of Tensile Strength Data

The ASTM Brazilian disc graphite strength (splitting tensile strength, σ sts ) test method (ASTM D8289) is of interest because the small-specimen geometry is compatible with that of environmental effects specimens, thus allowing for environmental effects such as irradiation, irradiation creep, or oxidation on tensile strength to be investigated. The Brazilian disc strength of Mersen grade 2114 graphite is reported and compared with strength data previously obtained using larger cylindrical ASTM dog-bone specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Understanding the crack formation of graphite particles in cycled commercial lithium-ion batteries by focused ion beam - scanning electron microscopy

Here in this paper, the structure degradation of commercial Lithium-ion battery (LIB) graphite anodes with different cycling numbers and charge rates was investigated by focused ion beam (FIB) and scanning electron microscopy (SEM). The cross-section image of graphite anode by FIB milling shows that cracks, resulted in the volume expansion of graphite electrode during long-term cycling, were formed in parallel with the current collector. The crack occurs in the bulk of graphite particles near the lithium insertion surface, which might derive from the stress induced during lithiation and de-lithiation cycles. Subsequently, crack takes place along grain boundaries of the polycrystalline graphite, but only in the direction parallel with the current collector. Furthermore, fast charge graphite electrodes are more prone to form cracks since the tensile strength of graphite is more likely to be surpassed at higher charge rates. Therefore, for LIBs long-term or high charge rate applications, the tensile strength of graphite anode should be taken into account.

25 ENERGY STORAGE↗
DOE OSTI2020

Mersen Grade 2114: Tensile Strength from Brazilian Disc Testing

The ASTM Brazilian disc graphite strength (splitting tensile strength, σ sts ) test method (ASTM D8289) is of interest because the small-specimen geometry is compatible with that of environmental effects specimens, thus allowing for environmental effects such as irradiation, irradiation creep, or oxidation on tensile strength to be investigated. The Brazilian disc strength of Mersen grade 2114 graphite (billet 116310 slab 1) is reported and compared with strength data previously obtained using larger cylindrical ASTM dog-bone specimens and with Brazilian disc strength data obtained from billet 116310 slab 5.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Analysis Of Fracture Location on Tensile Graphite Samples

The main standard for testing the ultimate tensile strength of graphite is ASTM C749. Commercial entities have raised concerns about samples breaking outside of the gauge section, particularly in the radius or head of the sample. When this occurs, the data gathered from the samples is unusable and increases the cost of testing as more samples will need to be machined. This study investigates the locations and frequency of sample breakage for four different grades of graphite using a custom-made measurement scale. The four grades include two fine-grain (2114 and IG-110) and two medium/coarse-grain (NBG-17 and PCEA). Our results show that fine-grain grades are more susceptible to breaking outside the gauge section, with almost 30% of the samples from grade 2114 breaking outside this region. Additionally, the radius being too small causes stress concentrations near the ends of the gauge section resulting in a bimodal distribution of the fracture locations.

36 - MATERIALS SCIENCE↗
NASA NTRS1987

Effect of dropped plies on the strength of graphite-epoxy laminates

The reduction in the compressive and tensile strengths of graphite-epoxy laminates with thickness discontinuities due to dropped plies was studied by experiment and analysis. The specimens were fabricated with all the dropped plies lumped together in the center of a sixteen-ply quasi-isotropic layup, such that one surface was flat and the slope of the opposite surface changed abruptly at the dropped ply location to accommodate the thickness change. Even though the thick and thin sections are symmetrically laminated, there exists bending-extension coupling due to the geometric eccentricity of the middle planes of the thick and thin sections. Experiments were conducted on fifty-four specimens that differed in the configuration of the dropped plies only. The strength of a laminate with dropped plies is less than the strength of its thin section, and the compressive strength of a laminate with dropped plies is less than its tensile strength. The reduction in strength is directly related to the axial stiffness change between the thick and thin sections. To examine the mechanism of failure, the three-dimensional state of stress in the dropped ply region was evaluated by the finite element method. A tensile interlaminar criterion predicted the correct location of failure, but underestimated the failure load.

Curry, James M.↗
NASA NTRS1979

Tensile and flexural strength of non-graphitic superhybrid composites: Predictions and comparisons

Equations are presented and described which can be used to predict bounds on the tensile and flexural strengths of nongraphitic superhybrid (NGSH) composites. These equations are derived by taking into account the measured stress-strain behavior, the lamination residual stresses and the sequence of events leading to fracture. The required input for using these equations includes constituents, properties (elastic and strength), NGSH elastic properties, cure temperature, and ply stress influence coefficients. Results predicted by these equations are in reasonably good agreement with measured data for strength and for the apparent knees in the nonlinear stress-strain curve. The lower bound values are conservative compared to measured data. These equations are relatively simple and are suitable for use in the preliminary design and initial sizing of structural components made from NGSH composites.

Chamis, C. C.↗
DOE OSTI2015

Negative pressure and spallation in graphite targets under nano- and picosecond laser irradiation

We present the results of experiments on the spallation phenomena in graphite targets under shock-wave nano- and picosecond irradiation, which have been performed on Kamerton-T (GPI, Moscow, Russia) and PHELIX (GSI, Darmstadt, Germany) laser facilities. In the range of the strain rates of 10{sup 6} – 10{sup 7} s{sup -1}, the data on the dynamic mechanical strength of the material at rapure (spallation) have been for the first time obtained. With a maximal strain rate of 1.4 × 10{sup 7} s{sup -1}, the spall strength of 2.1 GPa is obtained, which constitutes 64% of the theoretical ultimate tensile strength of graphite. The effect of spallation is observed not only on the rear side of the target, but also on its irradiated (front) surface. With the use of optical and scanning electron microscopes, the morphology of the front and rear surfaces of the targets is studied. By means of Raman scattering of light, the graphite structure both on the target front surface under laser exposure and on its rear side in the spall zone is investigated. A comparison of the dynamic strength of graphite and synthetic diamond is performed. (extreme light fields and their applications)

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2026

Computational modeling of graphite degradation in molten salt reactors: Role of infiltration

Molten salt reactors (MSRs) often employ graphite as a moderator and reflector. An important challenge for deploying graphite in these reactors is that, due to limited experimental data, our understanding of graphite’s structural integrity in molten salt environments remains incomplete. Here, this study addresses heat generation from fuel-bearing salt that has infiltrated open pores in the graphite, driven primarily by pressure differentials. This is one of multiple identified physical and chemical mechanisms through which molten salt could potentially degrade graphite. Thermally driven stresses are quantified using the Molten-Salt Reactor Experiment (MSRE) graphite moderator elements as a case study. Finite element simulations predict stress distributions at varying infiltration levels, indicating that thermal stresses increase with higher infiltration. Rare-event simulations using the parallel subset simulation framework identify the combinations and corresponding ranges of input parameters that lead to stresses above a specified threshold. In particular, combinations involving high infiltration amounts, high power density, and low thermal conductivity tend to induce the highest stresses. Under the inputs and assumptions considered in this work, the magnitudes of the thermally driven stresses are quite low, with a very low likelihood of causing failure due to exceeding the graphite’s tensile strength. Additionally, rare-event simulations were performed for two more scenarios: a scaled-up moderator geometry and a localized hotspot in the original geometry. Both cases resulted in increased susceptibility to failure, though not to a detrimental extent. Furthermore, the combined effects of irradiation and infiltration-induced thermal stresses were evaluated. The results showed that thermal stresses from infiltration were negligible compared to those caused by irradiation. The findings of such a study are inherently component-specific, but the methodology presented here could be used for similar assessments of salt-infiltration effects in other graphite components.

36 - MATERIALS SCIENCE↗
NASA NTRS1974

Tensile properties of an ultrahigh-strength graphite fiber in an epoxy matrix

The fiber performance and reinforcement potential for fiber composites of a special PAN-based graphite fiber were evaluated by testing the fiber's tensile properties in an epoxy matrix. Representative strand samples were taken from 30 spools of single-end, 1500-filament fiber to make over 5000 fiber/epoxy strand specimens using the filament-winding process. Characteristics studied were fiber uniformity, strength and modulus distributions at room and liquid-nitrogen temperatures, stress-strain behavior, the effect of strain rate on fiber strength, and acoustic emission during tensile loading to failure. The fiber was found to have a 3570-MPa failure stress, a 1.7% failure strain, a 206-GPa modulus, and a density of 1.77 Mg/cu m at 23 C. Liquid-nitrogen temperature and various strain rates had no significant effect on fiber tensile properties.

Chiao, T. T.↗
DOE OSTI2026

Investigation of nonlinear mechanical behavior of two superfine-grained graphites with DIC assisted disc splitting test

Using standardized uniaxial tensile test specimens is not practical due to the limited volumes in irradiation capsules, molten salt degradation facilities, or oxidation apparatus. The ASTM International Standard Test Method for Tensile Strength Estimate by Disc Compression of Manufactured Graphite (ASTM D8289) was developed to provide a convenient way for estimating tensile strength. Unlike the traditional uniaxial tensile test in ASTM C749 (International Standard Test Method for Tensile Stress–Strain of Carbon and Graphite), which uses dog-bone shaped specimens larger than 12.95 mm × 120.65 mm, the ASTM D8289 standard uses smaller discs with diameters of 6–12.7 mm. A digital image correlation (DIC) system, which uses a full-field noncontact surface displacement measurement technique, was applied along with the ASTM D8289 disc splitting test on IG-110 samples and compared with previous measurements from Mersen 2114 samples. Results confirmed that the DIC technique can measure the surface displacement/strain on these small (Ø6 mm × 3 mm) graphite specimens with good repeatability. However, Mersen 2114 and IG-110 samples exhibited strain discrepancies when DIC measurements were compared with analytical and finite element simulation values. The loading history and strain results also indicated different mechanical behaviors between Mersen 2114 and IG-110, particularly the nonlinear behavior of the IG-110 samples. Good agreement was observed by comparing the splitting tensile strengths of two superfine-grained grades with results from other work. The specimen size effect is discussed when comparing the splitting tensile strength with corresponding uniaxial tensile strength of these two graphite grades.

Lin, Lianshan [ORNL] (ORCID:0000000203399219)↗
DOE OSTI2024

UNDERSTANDING THE SEMI-PROBABILISTIC APPROACHES IN STRUCTURAL RELIABILITY USED TO SET DESIGN RELIABILITY TARGETS FOR GRAPHITE COMPONENTS USING ASME BPVC METHODS

Graphite is a quasi-brittle material, resulting in random variability in tensile strength distributions. To account for the random variability in strength, HHA-3000 of the ASME BPVC provides two semi-probabilistic methods for qualifying nuclear graphite components in the design stage, the simplified and full assessments. The full and simplified assessments apply statistical methods to engineering-based design problems. This is often referred to as reliability-based design. Reliability-based design (RBD) is a method to develop reliable designs by accounting for uncertainties and result in small chances of failure when also considering safety factors. RBDs provide reliability targets using semi-probabilistic approaches. RBD is implemented in ASME BPVC HHA-3000 for nuclear graphite components, but is not specific to that application. There has been much confusion around the methods implemented in ASME BPVC HHA-3000 for qualifying nuclear graphite components. To address the confusion, this paper takes a hierarchical approach. First, the general RBD framework is presented. Then, the semi-probabilistic methods and the underlying assumptions implemented in the assessments are presented. The semi-probabilistic methods are separated from the engineering modifications that have been made to the assessments. After building the framework and underlying assumptions, the specific methods in the full and simplified assessments are explained in three steps: inputs, methods, outputs. The methods are applied to an H-451 reflector block. Tensile strength properties for other graphite grades are provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Evaluation of the Simplified Assessment Peak Equivalent Stress Design Limit Probability of Failure

The ASME Boiler and Pressure Vessel Code Section III Division 5 Subsection HH Subpart A (HHA) outlines requirements and qualification methods for graphite core components in high temperature reactor environments. One such structural qualification method is the Simplified Assessment outlined in HHA-3220, which represents a comparison of service level specific equivalent stresses to allowable stress values derived from target probability of failures (POFs). The target POF is based on the structural reliability class (SRC) for the components and service condition of interest, and is used to establish design limits for combined membrane and peak equivalent stresses. Combined membrane stress limits are derived from two parameter Weibull distribution fits of the graphite grade specific tensile strength data and the target POF. The combined membrane stress limits are then scaled based on the ratio of flexural strength to tensile strength (referred hereinafter as Rtf) to establish the corresponding peak equivalent stress limits. It is desired that the target POF is at least maintained for both combined membrane and peak equivalent design limits, especially with the use of Rtf. The assessment presented herein examines tensile and flexural data for medium and fine grade graphites relative to the calculated combined membrane and peak equivalent stress limits per HHA-3220 and illustrates the simplified assessment method results in anticipated, or at least conservative, peak equivalent design stress limits.

36 - MATERIALS SCIENCE↗
DOE OSTI2015

PCEA Baseline Characterization: Billet XCP01S8 11 Compressive, Tensile, and Flexure Strengths

Grade PCEA graphite is one of several grades being considered for the core structures of the Next Generation Nuclear Plant (NGNP). An experimental program is underway to describe the statistical nature of the mechanical properties of PCEA graphite, information needed to support the design of graphite components and licensing of the NGNP. It will be necessary to characterize several billets from various lots or batches. The exact number of billets will depend on the observed variability in properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗