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Christopher A. Kantzos

Publications and source records attributed to Christopher A. Kantzos.

7 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Effects of Oxide Dispersion on Failure Modes in an Additively Manufactured Superalloy

Additive manufacturing opens new paths for introducing oxide particles into superalloys, to potentially provide oxide dispersion strengthening (ODS) at high temperatures. This provides opportunities to study how such dispersions can influence failure modes for a given superalloy, after nearly identical material processing paths. The objective of this study was to compare monotonic failure modes for additively manufactured superalloys with versus without an introduced oxide dispersion. The superalloy for each case was produced by laser powder bed fusion additive manufacturing. Specimens were subsequently given consistent thermal treatment paths and then tested in tensile and creep tests at varied temperatures. Failure modes were then compared. Additively manufactured NiCrAl without ODS had randomly oriented equiaxed grains while this alloy with 0.25 wt% Y 2 O 3 ODS additions had elongated [001] oriented grains in the build direction. Material made without ODS (“No-ODS”) was nearly completely single phase gamma, while ODS additions resulted in gamma, chromium carbide, and Y-Al-Cr oxide phases, with carbide and oxide phases contents estimated at no more than 13 and 1 vol%, respectively. Compared to No-ODS, material made with ODS had higher tensile strengths at room, 760 and 1093 °C. The elongation of ODS material was lower than No-ODS at room temperature, but higher at 760 °C. At 1093 °C ODS material had higher elongation than No-ODS when tested in the build direction, however elongation was lower for ODS material in the transverse direction at 1093 °C. Creep rupture strain, life, and area reduction at 760 and 1093 °C were all much higher for ODS material compared to No-ODS; 760 °C rupture life was nearly 100 times longer for ODS material. The presence of Y in the ODS material significantly improved oxidation resistance.

supperalloys↗
NASA NTRS2024

Agency Additive Manufacturing (AM) Certification Support Team (AACT) Risk Reduction – Safe Life Category: Fracture Control Framework for Un-inspectable Fracture Critical AM Parts

The NASA Engineering and Safety Center (NESC) was requested to support the development of a governing philosophy to provide a consistent and systematic approach for fracture control certification of additive manufacturing (AM) hardware that cannot be reliably inspected. The overall goal of the NESC assessment was to make progress toward a framework for general certification of un-inspectable fracture critical AM hardware and toward approaches for evaluating risks associated with these components. This report contains the results of the assessment.

Additive Manufacturing↗
NASA NTRS2023

Recrystallization of A Shot Peened Single Crystal Nickel-Base Superalloy

Single crystal nickel-base superalloys used as turbine engine airfoils can have much higher creep and thermal fatigue resistance required for blades and vanes than polycrystalline superalloys due to the absence of weak grain boundaries, as well as the low elastic modulus in the [001] single crystal growth direction (Refs. 1 and 2). This has allowed an increase in the turbine rim inlet temperatures for improved performance and efficiency. However, these advantages in performance require constraints on acceptable levels of single crystal defects, such as macroscopic grain boundaries at low angles to the primary grain (i.e., low angle boundaries or LAB), higher angle boundaries, small new grains nucleated at the blade surface (a.k.a. freckles), larger new grains, and also the single crystal blades’ orientation, typically degrees off of the [001] direction and the orientation of a transverse [010] direction with respect to blade geometry. Therefore, single crystal turbine airfoils, which are frequently used with as-cast surfaces, are grain etched and inspected before and after heat treatments to ensure these aspects conform to acceptability limits.

single crystal↗
NASA NTRS2023

A 3D Printable Alloy Designed for Extreme Environments

Multiprincipal-element alloys are an enabling class of materials owing to their impressive mechanical and oxidation-resistant properties, especially in extreme environments. Here we develop a new oxide-dispersion-strengthened NiCoCr-based alloy using a model-driven alloy design approach and laser-based additive manufacturing. This oxide-dispersion-strengthened alloy, called GRX-810, uses laser powder bed fusion to disperse nanoscale Y 2 O 3 particles throughout the microstructure without the use of resource-intensive processing steps such as mechanical or in situ alloying. We show the successful incorporation and dispersion of nanoscale oxides throughout the GRX-810 build volume via high-resolution characterization of its microstructure. The mechanical results of GRX-810 show a twofold improvement in strength, over 1,000-fold better creep performance and twofold improvement in oxidation resistance compared with the traditional polycrystalline wrought Ni-based alloys used extensively in additive manufacturing at 1,093 °C. The success of this alloy highlights how model-driven alloy designs can provide superior compositions using far fewer resources compared with the ‘trial-and-error’ methods of the past. These results showcase how future alloy development that leverages dispersion strengthening combined with additive manufacturing processing can accelerate the discovery of revolutionary materials.

Timothy M. Smith↗
NASA NTRS2023

Competition of Failure Modes in an Additively Manufactured Disk Superalloy

Additive manufacturing of powder metallurgy (PM) disk superalloys can produce unique microstructures that differ from those usually encountered in traditional processing as the result of consolidation, forging, and heat treatments. Unusual variations in grain size, major and minor phase precipitate sizes, and defects can occur. The failure modes associated with these unique microstructures are of high interest. The objective of this study was to compare the failure modes for a low solvus, high refractory (LSHR) PM disk superalloy produced by electron-beam-melting additive manufacturing. Specimens were subsequently given different solution heat treatments and a fixed aging heat treatment. Tensile, creep, and fatigue failure modes were screened in tests at elevated temperatures. Failure modes were considered with respect to these unique microstructures.

additive manufacturing↗
NASA NTRS2023

Influences of Varied Electrical Discharge Machining Operations on Surface Conditions of Several Nickel-Based Superalloys

Nickel-based superalloys designed for use in gas turbine engines blades are difficult and expensive to properly machine without undue surface damage, due in part to their superior mechanical properties at high temperatures. Numerically controlled electrical discharge machining (EDM) has progressed to commonly be used as a machining process for initial sectioning, detailed roughing, and even some finishing operations. The objective of this study was to examine the effect of EDM on resulting surface conditions of superalloy 718 after slicing using typical rough, semi-finish, and finish condition sets with a typical wire EDM machine. Surface roughness, residual stress, and microstructures were compared for these conditions. The varied EDM conditions influenced surface roughness as intended. The residual stresses and surface roughness directly corresponding to the EDM steps were determined. While roughness decreased when progressing from rough to finish EDM conditions, tensile residual stresses unexpectedly increased. Brief assessments after EDM of two higher performance powder metallurgy disk superalloys ME209 and LSHR indicated this inverse relationship of roughness versus tensile residual stress was also present for these superalloys, where tensile residual stresses were significantly enhanced.

superalloys↗