Using Established Wrought Strength Trends to Inform Additively Manufactured Strength Trends
Explore the source record for details and available documents.
additive manufacturing↗
Engineering topics
Colton C Katsarelis
Publications and source records attributed to Colton C Katsarelis.
L-PBF Ni-201 Feasibility Study Materials Characterization Summary
Nickel 200 and 201 are commercially pure nickel alloys with Ni-201 having a lower carbon content than Ni-200.These alloys are useful for their excellent corrosion resistance, good thermal conductivity, and mechanical properties. Very little information has been published on additive manufacturing (AM) of either Ni-200 or Ni-201, so a feasibility study to produce coupons with Ni-201 powder was performed. This work was carried out at NASA MSFC and Aerojet Rocketdyne. Contributors at NASA MSFC included Brian West, Zack Jones, Colton Katsarelis, and Matt Medders in collaboration with Dan Matejczyk and Alison Park at Aerojet Rocketdyne. The data provided in this report was collected by the MSFC. This feasibility study aimed to do the following
Nickel 201↗
Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications
The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.
Po S Chen↗