Stan G. Pitman

Weld metal ductility in aluminum tailor welded blanks

The objective of the research described in this article was to characterize and numerically describe the ductility of weld material in aluminum tailor welded blanks under uniaxial tension conditions. Aluminum tailor welded blanks consist of multiple thickness and alloy sheet materials welded together into a single, variable thickness blank. To evaluate the mechanical properties of the weld material in these tailor welded blanks, a series of tensile specimens containing varying ratios of weld and monolithic material in the gage area of the specimen were tested. These experimental results show that increasing the amount of weld in the cross-sectional area of the specimen decreases the ductility of the specimen and that the weld characteristics have a pronounced impact on ductility. Using the experimental results and classical tensile instability and necking models, a numerical model was developed to describe the ductility of the weld metal. The model involves basic material properties and an initial imperfection level in both the weld and monolithic materials. The specimens studied were produced from 1- to 2-mm AA5182-O aluminum alloy sheet material welded into blanks using an autogenous gas tungsten arc welding process.

High-pressure hydrogen materials compatibility of piezoelectric films

Hydrogen is well known for materials compatibility issues, including blistering and embrittlement in metals, which are challenges for its use as the next-generation “green” fuel. Beyond metals, hydrogen also degrades piezoelectric materials used as actuators used in direct injection hydrogen internal combustion engines. We present the materials compatibility studies of piezoelectric films in high-pressure hydrogen environments. Absorption of high-pressure hydrogen and composition changes were studied with an elastic recoil detection analysis and Rutherford back-scattering spectrometry in lead zirconate titanate and barium titanate thin films. Hydrogen surface degradation in the form of blistering and Pb mixing was also observed.

Hydrogen species motion in piezoelectrics: A quasi-elastic neutron scattering study

Hydrogen is known to damage or degrade piezoelectric materials, at low pressure for ferroelectric random access memory applications, and at high pressure for hydrogen-powered vehicle applications. The piezoelectric degradation is in part governed by the motion of hydrogen species within the piezoelectric materials. We present here quasi-elastic neutron scattering (QENS) measurements of the local hydrogen species motion within lead zirconate titanate (PZT) and barium titanate (BTO) on samples charged by exposure to high-pressure gaseous hydrogen (≈17 MPa). Neutron vibrational spectroscopy (NVS) studies of the hydrogen-enhanced vibrational modes are presented as well. Results are discussed in the context of theoretically predicted interstitial hydrogen lattice sites and compared to comparable bulk diffusion studies of hydrogen diffusion in lead zirconate titanate.

Pb nanowire formation on Al/lead zirconate titanate surfaces in high-pressure hydrogen

Piezoelectric systems are well known to degrade in hydrogen because of various mechanisms including loss of polarization, Pb migration into the electrode, and surface blistering. Understanding damage mechanisms is crucial for potential high-pressure applications such as injectors for hydrogen-fueled vehicles. In this paper, we report on a previously unreported form of high-pressure hydrogen damage resulting from growth of surface Pb nanowires from an Al electrode on lead zirconate titanate. Wires were observed with roughly 80 nm diameter and with length that varied between 5 and 100 μm. Microscopy to characterize the nanowires and ion-scattering measurements to quantify concurrent Pb surface migration and hydrogen absorption effects are described.

An in situ tensile test apparatus for polymers in high pressure hydrogen

Degradation of material properties by high-pressure hydrogen is an important factor in determining the safety and reliability of materials used in high-pressure hydrogen storage and delivery. Hydrogen damage mechanisms have a time dependence that is linked to hydrogen outgassing after exposure to the hydrogen atmosphere that makes ex situ measurements of mechanical properties problematic. Designing in situ measurement instruments for high-pressure hydrogen is challenging due to known hydrogen incompatibility with many metals and standard high-power motor materials such as Nd. Here we detail the design and operation of a solenoid based in situ tensile tester under high-pressure hydrogen environments up to 42 MPa (6000 psi). Modulus data from high-density polyethylene samples tested under high-pressure hydrogen at 35 MPa (5000 psi) are also reported as compared to baseline measurements taken in air.

Hydrogen diffusion in lead zirconate titanate and barium titanate

Hydrogen is a potential clean-burning, next-generation fuel for vehicle and stationary power. Unfortunately, hydrogen is also well known to have serious materials compatibility issues in metals, polymers, and ceramics. Piezoelectric actuator materials proposed for low-cost, high efficiency high-pressure hydrogen internal combustion engines (HICE) are known to degrade rapidly in hydrogen. This limits their potential use and poses challenges for HICE. Hydrogen-induced degradation of piezoelectrics is also an issue for low-pressure hydrogen passivation in ferroelectric random access memory. Currently, there is a lack of data in the literature on hydrogen species diffusion in piezoelectrics in the temperature range appropriate for the HICE as charged via a gaseous route. We present 1HNMR quantification of the local hydrogen species diffusion within lead zirconate titanate and barium titanate on samples charged by exposure to high-pressure gaseous hydrogen ∼32 MPa. Results are discussed in context of theoretic...

An in situ tribometer for measuring friction and wear of polymers in a high pressure hydrogen environment

High pressure hydrogen effects on the friction and wear of polymers are of importance to myriad applications. Of special concern are those used in the infrastructure for hydrogen vehicle refueling stations, including compressor sliding seals, valves, and actuators. While much is known about potentially damaging embrittlement effects of hydrogen on metals, relatively little is known about the effects of high pressure hydrogen on polymers. However, based on the limited results that are published in the literature, polymers also apparently exhibit compatibility issues with hydrogen. An additional study is needed to elucidate these effects to avoid incompatibilities either through design or material selection. As part of this effort, we present here in situ high pressure hydrogen studies of the friction and wear on example polymers. To this end, we have built and demonstrated a custom-built pin-on-flat linear reciprocating tribometer and demonstrated its use with in situ studies of friction and wear behavior of nitrile butadiene rubber polymer samples in 28 MPa hydrogen. Tribology results indicate that friction and wear is increased in high pressure hydrogen as compared both with values measured in high pressure argon and ambient air conditions.

In Situ High Pressure Hydrogen Tribological Testing of Common Polymer Materials Used in the Hydrogen Delivery Infrastructure

High pressure hydrogen gas is known to adversely affect metallic components of compressors, valves, hoses, and actuators. However, relatively little is known about the effects of high pressure hydrogen on the polymer sealing and barrier materials also found within these components. More study is required in order to determine the compatibility of common polymer materials found in the components of the hydrogen fuel delivery infrastructure with high pressure hydrogen. As a result, it is important to consider the changes in physical properties such as friction and wear in situ while the polymer is exposed to high pressure hydrogen. In this protocol, we present a method for testing the friction and wear properties of ethylene propylene diene monomer (EPDM) elastomer samples in a 28 MPa high pressure hydrogen environment using a custom-built in situ pin-on-flat linear reciprocating tribometer. Representative results from this testing are presented which indicate that the coefficient of friction between the EPDM sample coupon and steel counter surface is increased in high pressure hydrogen as compared to the coefficient of friction similarly measured in ambient air.

Progress towards prognostic health management of passive components in advanced reactors — Model selection and evaluation

This paper presents recent progress towards developing a prognostic health management framework for passive components of advanced reactors (AR). The focus of this paper is on lifecycle prognostics for passive components using a Bayesian prognostic algorithm that provides a natural framework for incorporating different sources of variability and uncertainties inherent in the operations of AR. High-temperature creep damage, a prototypic failure mechanism in AR materials, is used as the context for this research. A Bayesian model selection approach is implemented to select the appropriate creep degradation model at any given time, using relevant sensor measurements reflecting the material degradation state. The model selection approach, based on reversible jump Markov chain Monte Carlo methods, is integrated with Bayesian particle filter-based prognostic framework. The proposed approach is evaluated using strain measurements obtained from accelerated creep testing of stainless steel specimens. Results indicate feasibility of the proposed approach in accurately identifying the creep degradation stage from the available measurements at a given time. Effect of uncertainties in material degradation model and measurement noise on the performance of the prognostic algorithm is also investigated.

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.