Publications

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In the absence of pre-existing failure-critical defects, the fracture or tearing process in deformable metals loaded in tension begins with the nucleation of internal cavities or voids in regions of elevated triaxial stress. While ductile rupture processes initiate at inclusions or precipitates in many alloys, nucleation in pure metals is often assumed to be associated with grain boundaries or triple junctions. This study presents ex situ observations of incipient, subsurface void nucleation in pure tantalum during interrupted uniaxial tensile tests using electron channeling contrast (ECC) imaging, electron backscatter diffraction (EBSD), transmission Kikuchi diffraction (TKD) and transmission electron microscopy (TEM). Instead of forming at grain boundaries, voids initiated at and grew along dislocation cell and cell block boundaries created by plastic deformation. Most of the voids were associated with extended, lamellar deformation-induced boundaries that run along the traces of the {110} or {112} planes, though a few voids initiated at low-angle dislocation subgrain boundaries. In general, a high density of deformation-induced boundaries was observed near the voids. TEM and TKD demonstrate that voids initiate at and grow along cell block boundaries. Two mechanisms for void nucleation in pure metals, vacancy condensation and stored energy dissipation, are discussed in light of these results. The observations of the present investigation suggest that voids in pure materials nucleate by vacancy condensation and subsequently grow by consuming dislocations.

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The Structural Reliability Partnership Workshop was held in Albuquerque, NM on August 29-30, 2017 and was hosted by Sandia National Laboratories. Attendees were present from academia, industry and several other national laboratories. The workshop kicked off with an introduction to the SRP to familiarize potential members with what the purpose, structure and benefits would be to their organization. Technical overviews were given on several topics by attendees from each sector – national labs, universities and industry – to provide a snapshot of the type of work that is currently being conducted on structural reliability. Attendees were then given the opportunity to suggest and discuss potential Challenge Scenario topics. Three were ultimately decided upon as being the most important: Additive Manufacturing, Hydrogen Pipeline Steels, and Bolted Joined Structures. These were then analyzed using Quad Charts to determine What, How, Who, and Why these areas would be further investigated. Rather than restricting future research to only one area, the option was left open to investigate both the top two, depending on interest and cost associated with hosting such an event. More informal collaboration may be undertaken for the third topic if members have time and interest. Other items discussed pertained to the organization, structure and policies of the Partnership. Topics including Data Management, IP, and mechanisms of partnering/information sharing were touched upon but final decisions were not made. Further action is needed before this can be done. Action items were outlined and assigned, where possible. The next workshop is to be held in early August 2018 in Boulder, CO and is to be hosted by NIST. In the interim, quarterly updates are to take place via WebEx to maintain a line of communication and to ensure progress on both the administrative and technical tasks.

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Additive manufacturing enables the rapid, cost effective production of customized structural components. To fully capitalize on the agility of additive manufacturing, it is necessary to develop complementary high-throughput materials evaluation techniques. In this study, over 1000 nominally identical tensile tests are used to explore the effect of process variability on the mechanical property distributions of a precipitation hardened stainless steel produced by a laser powder bed fusion process, also known as direct metal laser sintering or selective laser melting. With this large dataset, rare defects are revealed that affect only ≈2% of the population, stemming from a single build lot of material. The rare defects cause a substantial loss in ductility and are associated with an interconnected network of porosity. The adoption of streamlined test methods will be paramount to diagnosing and mitigating such dangerous anomalies in future structural components.

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Additive manufacturing offers unprecedented opportunities to design complex structures optimized for performance envelopes inaccessible under conventional manufacturing constraints. Additive processes also promote realization of engineered materials with microstructures and properties that are impossible via traditional synthesis techniques. Enthused by these capabilities, optimization design tools have experienced a recent revival. The current capabilities of additive processes and optimization tools are summarized briefly, while an emerging opportunity is discussed to achieve a holistic design paradigm whereby computational tools are integrated with stochastic process and material awareness to enable the concurrent optimization of design topologies, material constructs and fabrication processes.

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