Temperature effects on the mechanical properties of annealed and HERF 304L stainless steel.

The effect of temperature on the tensile properties of annealed 304L stainless steel and HERF 304L stainless steel forgings was determined by completing experiments over the moderate range of -40 F to 160 F. Temperature effects were more significant in the annealed material than the HERF material. The tensile yield strength of the annealed material at -40 F averaged twenty two percent above the room temperature value and at 160 F averaged thirteen percent below. The tensile yield strength for the three different geometry HERF forgings at -40 F and 160 F changed less than ten percent from room temperature. The ultimate tensile strength was more temperature dependent than the yield strength. The annealed material averaged thirty six percent above and fourteen percent below the room temperature ultimate strength at -40 F and 160 F, respectively. The HERF forgings exhibited similar, slightly lower changes in ultimate strength with temperature. For completeness and illustrative purposes, the stress-strain curves are included for each of the tensile experiments conducted. The results of this study prompted a continuation study to determine tensile property changes of welded 304L stainless steel material with temperature, documented separately

Propagating Stress-Strain Curve Variability in Multi-Material Problems: Temperature-Dependent Material Tests to Plasticity Models to Structural Failure Predictions

This chapter presents a practical methodology for characterizing and propagating the effects of temperature-dependent material strength and failure-criteria variability to structural model predictions. The application involves a cylindrical canister (“can”) heated and pressurized to failure. Temperature dependence and material sample-to-sample stochastic variability are inferred from very limited experimental data of a few replicate uniaxial tension tests at each of seven temperatures spanning the 800°C temperature excursion experienced by the can, for each of several stainless steel alloys that make up the can. The load-displacement curves from the material tests are used to determine effective temperature-dependent stress-strain relationships in ductile-metal plasticity models used in can-level model predictions. Particularly challenging aspects of the problem are the appropriate inference, representation, and propagation of temperature dependence and material stochastic variability from just a few experimental data curves at a few temperatures (as sparse discrete realizations or samples from a random field of temperature-dependent stress-strain behavior), for multiple such materials involved in the problem. Currently unique methods are demonstrated that are relatively simple and effective

Validation of thermal-mechanical modeling of stainless steel forgings

A constitutive model for recrystallization has been developed within the framework of an existing dislocation-based rate and temperature-dependent plasticity model. The theory has been implemented and tested in a finite element code. Material parameters were fit to data from monotonic compression tests on 304L steel for a wide range of temperatures and strain rates. The model is then validated by using the same parameter set in predictive thermal-mechanical simulations of experiments in which wedge forgings were produced at elevated temperatures. Model predictions of the final yield strengths compare well to the experimental results

A mechanism-based approach to modeling ductile fracture.

Ductile fracture in metals has been observed to result from the nucleation, growth, and coalescence of voids. The evolution of this damage is inherently history dependent, affected by how time-varying stresses drive the formation of defect structures in the material. At some critically damaged state, the softening response of the material leads to strain localization across a surface that, under continued loading, becomes the faces of a crack in the material. Modeling localization of strain requires introduction of a length scale to make the energy dissipated in the localized zone well-defined. In this work, a cohesive zone approach is used to describe the post-bifurcation evolution of material within the localized zone. The relations are developed within a thermodynamically consistent framework that incorporates temperature and rate-dependent evolution relationships motivated by dislocation mechanics. As such, we do not prescribe the evolution of tractions with opening displacements across the localized zone a priori. The evolution of tractions is itself an outcome of the solution of particular, initial boundary value problems. The stress and internal state of the material at the point of bifurcation provides the initial conditions for the subsequent evolution of the cohesive zone. The models we develop are motivated by in-situ scanning electron microscopy of three-point bending experiments using 6061-T6 aluminum and 304L stainless steel, The in situ observations of the initiation and evolution of fracture zones reveal the scale over which the failure mechanisms act. In addition, these observations are essential for motivating the micromechanically-based models of the decohesion process that incorporate the effects of loading mode mixity, temperature, and loading rate. The response of these new cohesive zone relations is demonstrated by modeling the three-point bending configuration used for the experiments. In addition, we survey other methods with the potential to provide more detailed information about the near tip deformation fields

High fidelity frictional models for MEMS.

The primary goals of the present study are to: (1) determine how and why MEMS-scale friction differs from friction on the macro-scale, and (2) to begin to develop a capability to perform finite element simulations of MEMS materials and components that accurately predicts response in the presence of adhesion and friction. Regarding the first goal, a newly developed nanotractor actuator was used to measure friction between molecular monolayer-coated, polysilicon surfaces. Amontons law does indeed apply over a wide range of forces. However, at low loads, which are of relevance to MEMS, there is an important adhesive contribution to the normal load that cannot be neglected. More importantly, we found that at short sliding distances, the concept of a coefficient of friction is not relevant; rather, one must invoke the notion of 'pre-sliding tangential deflections' (PSTD). Results of a simple 2-D model suggests that PSTD is a cascade of small-scale slips with a roughly constant number of contacts equilibrating the applied normal load. Regarding the second goal, an Adhesion Model and a Junction Model have been implemented in PRESTO, Sandia's transient dynamics, finite element code to enable asperity-level simulations. The Junction Model includes a tangential shear traction that opposes the relative tangential motion of contacting surfaces. An atomic force microscope (AFM)-based method was used to measure nano-scale, single asperity friction forces as a function of normal force. This data is used to determine Junction Model parameters. An illustrative simulation demonstrates the use of the Junction Model in conjunction with a mesh generated directly from an atomic force microscope (AFM) image to directly predict frictional response of a sliding asperity. Also with regards to the second goal, grid-level, homogenized models were studied. One would like to perform a finite element analysis of a MEMS component assuming nominally flat surfaces and to include the effect of roughness in such an analysis by using a homogenized contact and friction models. AFM measurements were made to determine statistical information on polysilicon surfaces with different roughnesses, and this data was used as input to a homogenized, multi-asperity contact model (the classical Greenwood and Williamson model). Extensions of the Greenwood and Williamson model are also discussed: one incorporates the effect of adhesion while the other modifies the theory so that it applies to the case of relatively few contacting asperities

Final LDRD report : metal oxide films, nanostructures, and heterostructures for solar hydrogen production.

The distinction between electricity and fuel use in analyses of global power consumption statistics highlights the critical importance of establishing efficient synthesis techniques for solar fuels-those chemicals whose bond energies are obtained through conversion processes driven by solar energy. Photoelectrochemical (PEC) processes show potential for the production of solar fuels because of their demonstrated versatility in facilitating optoelectronic and chemical conversion processes. Tandem PEC-photovoltaic modular configurations for the generation of hydrogen from water and sunlight (solar water splitting) provide an opportunity to develop a low-cost and efficient energy conversion scheme. The critical component in devices of this type is the PEC photoelectrode, which must be optically absorptive, chemically stable, and possess the required electronic band alignment with the electrochemical scale for its charge carriers to have sufficient potential to drive the hydrogen and oxygen evolution reactions. After many decades of investigation, the primary technological obstacle remains the development of photoelectrode structures capable of efficient conversion of light with visible frequencies, which is abundant in the solar spectrum. Metal oxides represent one of the few material classes that can be made photoactive and remain stable to perform the required functions

ASC-AD Penetration Modeling FY05 Status Report

Sandia currently lacks a high fidelity method for predicting loads on and subsequent structural response of earth penetrating weapons. This project seeks to test, debug, improve and validate methodologies for modeling earth penetration. Results of this project will allow us to optimize and certify designs for the B61-11, Robust Nuclear Earth Penetrator (RNEP), PEN-X and future nuclear and conventional penetrator systems. Since this is an ASC Advanced Deployment project the primary goal of the work is to test, debug, verify and validate new Sierra (and Nevada) tools. Also, since this project is part of the V&V program within ASC, uncertainty quantification (UQ), optimization using DAKOTA [1] and sensitivity analysis are an integral part of the work. This project evaluates, verifies and validates new constitutive models, penetration methodologies and Sierra/Nevada codes. In FY05 the project focused mostly on PRESTO [2] using the Spherical Cavity Expansion (SCE) [3,4] and PRESTO Lagrangian analysis with a preformed hole (Pen-X) methodologies. Modeling penetration tests using PRESTO with a pilot hole was also attempted to evaluate constitutive models. Future years work would include the Alegra/SHISM [5] and AlegrdEP (Earth Penetration) methodologies when they are ready for validation testing. Constitutive models such as Soil-and-Foam, the Sandia Geomodel [6], and the K&C Concrete model [7] were also tested and evaluated. This report is submitted to satisfy annual documentation requirements for the ASC Advanced Deployment program. This report summarizes FY05 work performed in the Penetration Mechanical Response (ASC-APPS) and Penetration Mechanics (ASC-V&V) projects. A single report is written to document the two projects because of the significant amount of technical overlap

Validation of thermal-mechanical modeling of stainless steel forgings

A constitutive model for recrystallization has been developed within the framework of an existing dislocation-based rate and temperature-dependent plasticity model. The theory has been implemented and tested in a finite element code. Material parameters were fit to data from monotonic compression tests on 304L steel for a wide range of temperatures and strain rates. The model is then validated by using the same parameter set in predictive thermal-mechanical simulations of experiments in which wedge forgings were produced at elevated temperatures. Model predictions of the final yield strengths compare well to the experimental results

J-Integral modeling and validation for GTS reservoirs.

Non-destructive detection methods can reliably certify that gas transfer system (GTS) reservoirs do not have cracks larger than 5%-10% of the wall thickness. To determine the acceptability of a reservoir design, analysis must show that short cracks will not adversely affect the reservoir behavior. This is commonly done via calculation of the J-Integral, which represents the energetic driving force acting to propagate an existing crack in a continuous medium. J is then compared against a material's fracture toughness (J{sub c}) to determine whether crack propagation will occur. While the quantification of the J-Integral is well established for long cracks, its validity for short cracks is uncertain. This report presents the results from a Sandia National Laboratories project to evaluate a methodology for performing J-Integral evaluations in conjunction with its finite element analysis capabilities. Simulations were performed to verify the operation of a post-processing code (J3D) and to assess the accuracy of this code and our analysis tools against companion fracture experiments for 2- and 3-dimensional geometry specimens. Evaluation is done for specimens composed of 21-6-9 stainless steel, some of which were exposed to a hydrogen environment, for both long and short cracks