Engineering topics

Draper, Susan L.

Publications and source records attributed to Draper, Susan L..

33 records · Page 2

NASA NTRS2003

Cost-Effective TiAl based Materials

Because of their inherent low ductility, TiAl-based materials are difficult to fabricate, especially thin gage titanium gamma aluminide (TiAl) sheet and foil. In this paper, an innovative powder metallurgy approach for producing cost-effective thin gage TiAl sheets (with 356 mm long and 235 mm wide, and a thickness of 0.74, 1.09, 1.55, and 2.34 mm, respectively) is presented. The microstructures and tensile properties at room and elevated temperatures of the thin gage TiAl are studied. Results show that these TiAl sheets have a relatively homogenous chemistry, uniform microstructure, and acceptable mechanical properties. This work demonstrates a cost-effective method for producing both flat products (sheet/foil) and complex chunky parts of TiAl for various advanced applications including aerospace and automotive industries.

Moxson, V. S.↗

NASA NTRS2003

Fretting Fatigue of Gamma TiAl Studied

Gamma titanium-aluminum alloy (g-TiAl) is an attractive new material for aerospace applications because of its low density and high specific strength in comparison to currently used titanium and nickel-base alloys. Potential applications for this material are compressor and low-pressure turbine blades. These blades are fitted into either the compressor or turbine disks via a dovetail connection. The dovetail region experiences a complex stress state due to the alternating centrifugal force and the natural high-frequency vibration of the blade. Because of the dovetail configuration and the complex stress state, fretting is often a problem in this area. Furthermore, the local stress state becomes more complex when the influence of the metal-metal contact and the edge of the contact is evaluated. Titanium and titanium-based alloys in the clean state exhibit strong adhesive bonds when in contact with themselves and other materials (refs. 1 and 2). This adhesion causes heavy surface damage and high friction in practical cases. Although the wear produced by fretting may be mild, the reduction in fatigue life can be substantial. Thus, there is the potential for fretting problems with these TiAl applications. Since TiAl is an emerging material, there has been limited information about its fretting behavior.

Miyoshi, Kazuhisa↗

NASA NTRS2002

Preliminary Study on Fatigue Strengths of Fretted Ti-48Al-2Cr-2Nb

The fatigue behavior (stress-life curve) of gamma titanium aluminide (Ti-48Al-2Cr-2Nb, atomic percent) was examined by conducting two tests: first, a fretting wear test with a fatigue specimen in contact with a typical nickel-based superalloy contact pad in air at temperatures of 296 and 823 K and second, a high-cycle fatigue test of the prefretted Ti-48Al-2Cr-2Nb fatigue specimen at 923 K. Reference high-cycle fatigue tests were also conducted with unfretted Ti-48Al-2Cr-2Nb specimens at 923 K. All Ti-48Al-2Cr-2Nb fatigue specimens were machined from cast slabs. The results indicate that the stress-life results for the fretted Ti-48Al-2Cr-2Nb specimens exhibited a behavior similar to those of the unfretted Ti-48Al-2Cr-2Nb specimens. The values of maximum stress and life for the fretted specimens were almost the same as those for the unfretted specimens. The resultant stress-life curve for the unfretted fatigue specimens was very flat. The flat appearance in the stress-life curve of the unfretted specimens is attributed to the presence of a high density of casting pores. The fatigue strengths of both the fretted and unfretted specimens can be significantly affected by the presence of this porosity, which can decrease the fatigue life of Ti-48Al-2Cr-2Nb. The presence of the porosity made discerning the effect of fretting damage on fatigue strength and life of the specimens difficult.

Miyoshi, Kazuhisa↗

NASA NTRS2002

Ti-48Al-2Cr-2Nb Evaluated Under Fretting Conditions

Material parameters govern many of the design decisions in any engineering task. When two materials are in contact and microscopically small, relative motions (either vibratory or creeping) occur, and fretting fatigue can result. Fretting fatigue is a material response influenced by the materials in contact as well as by such variables as loading and vibratory conditions. Fretting produces fresh, clean interacting surfaces and induces adhesion, galling, and wear in the contact zone. Time, money, and materials are unnecessarily wasted when galling and wear result in excessive fretting fatigue that leads to poorly performing, unreliable mechanical systems. Fretting fatigue is a complex problem of significant interest to aircraft engine manufacturers. It can occur in a variety of engine components. Numerous approaches, depending on the component and the operating conditions, have been taken to address the fretting problems. The components of interest in this investigation were the low-pressure turbine blades and disks. The blades in this case were titanium aluminide, Ti-48Al-2Cr- 2Nb, and the disk was a nickel-base superalloy, Inconel 718 (IN 718). A concern for these airfoils is the fretting in fitted interfaces at the dovetail where the blade and disk are connected. Careful design can reduce fretting in most cases, but not completely eliminate it, because the airfoils frequently have a skewed (angled) blade-disk dovetail attachment, which leads to a complex stress state. Furthermore, the local stress state becomes more complex when the influence of the metal-metal contact and the edge of contact are considered.

Miyoshi, Kazuhisa↗

NASA NTRS2001

Evaluation of Ti-48Al-2Cr-2Nb Under Fretting Conditions

The fretting behavior of Ti-48Al-2Cr-2Nb (y-TiAl) in contact with the nickel-base superalloy 718 was examined in air at temperatures from 296 to 823 K (23 to 550 C). The interfacial adhesive bonds between Ti-48Al-2Cr-2Nb and superalloy 718 were generally stronger than the cohesive bonds within Ti-48Al-2Cr-2Nb. The failed Ti-48Al-2Cr-2Nb debris subsequently transferred to the superalloy 718. In reference experiments conducted with Ti-6Al-4V against superalloy 718 under identical fretting conditions, the degree of transfer was greater for Ti-6A1-4V than for Ti-48Al-2Cr-2Nb. Wear of Ti-48Al-2Cr-2Nb generally decreased with increasing fretting frequency. The increasing rate of oxidation at elevated temperatures led to a drop in wear at 473 K. However, fretting wear increased as the temperature was increased from 473 to 823 K. At 723 and 823 K, oxide film disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.

Miyoshi, Kazuhisa↗

NASA NTRS2001

Fretting Wear of Ti-48Al-2Cr-2Nb

An investigation was conducted to examine the wear behavior of gamma titanium aluminide (Ti-48Al-2Cr-2Nb in atomic percent) in contact with a typical nickel-base superalloy under repeated microscopic vibratory motion in air at temperatures from 296-823 K. The surface damage observed on the interacting surfaces of both Ti-48Al-2Cr-2Nb and superalloy consisted of fracture pits, oxides, metallic debris, scratches, craters, plastic deformation, and cracks. The Ti-48Al-2Cr-2Nb transferred to the superalloy at all fretting conditions and caused scuffing or galling. The increasing rate of oxidation at elevated temperatures led to a drop in Ti-48Al-2Cr-2Nb wear at 473 K. Mild oxidative wear was observed at 473 K. However, fretting wear increased as the temperature was increased from 473-823 K. At 723 and 823 K, oxide disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Ti-48Al-2Cr-2Nb wear generally decreased with increasing fretting frequency. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals. Keywords

Miyoshi, Kazuhisa↗

NASA NTRS2001

Evaluation of Ti-48Al-2Nb Under Fretting Conditions

An investigation was conducted to examine the fretting behavior of lambda-TiAl (Ti-48Al-2Cr-2Nb) in contact with a nickel-base superalloy (Inconel 718) in air at temperatures from 23 to 550 C. Fretting wear experiments were conducted with 9.4-mm-diameter hemispherical Inconel (IN) 718 pins in contact with Ti-48Al-2Cr-2Nb flats (and the reverse) at loads from 1 to 40 N and fretting frequencies from 50 to 160 Hz with slip amplitudes from 50 to 200 microns for 1 to 20 million fretting cycles. The results were similar for both combinations of pin and flat. Reference fretting wear experiments were also conducted with 9.4-mm-diameter hemispherical Ti-6Al-4V pins in contact with IN718 flats. The interfacial adhesive bonds between Ti-48Al-2Cr-2Nb and IN718 in contact were generally stronger than the cohesive bonds in the cohesively weaker Ti-48Al-2Cr-2Nb. The failed Ti-48Al-2Cr-2Nb subsequently transferred to the IN718 surface at any fretting condition. The wear scars produced on Ti-48Al-2Cr-2Nb contained metallic and oxide wear debris, scratches, plastically deformed asperities, cracks, and fracture pits. Oxide layers readily formed on the Ti-48Al-2Cr-2Nb surface at 550 C, but cracks easily occurred in the oxide layers. Factors including fretting frequency, temperature, slip amplitude, and load influenced the fretting behavior of Ti-48Al-2Cr-2Nb in contact with IN718. The wear volume loss of Ti-48Al-2Cr-2Nb generally decreased with increasing fretting frequency. The increasing rate of oxidation at elevated temperatures up to 200 C led to a drop in wear volume loss at 200 C. However, the fretting wear increased as the temperature was increased from 200 to 550 C. The highest temperatures of 450 and 550 C resulted in oxide film disruption with generation of cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. The wear volume loss generally increased as the slip amplitude increased. The wear volume loss also generally increased as the load increased. Increasing slip amplitude and increasing load both tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.

Miyoshi, Kazuhisa↗

NASA NTRS2000

Damage Resistance of Titanium Aluminide Evaluated

As part of the aviation safety goal to reduce the aircraft accident rate, NASA has undertaken studies to develop durable engine component materials. One of these materials, g-TiAl, has superior high-temperature material properties. Its low density provides improved specific strength and creep resistance in comparison to currently used titanium alloys. However, this intermetallic is inherently brittle, and long life durability is a potential problem. Of particular concern is the material s sensitivity to defects, which may form during the manufacturing process or in service. To determine the sensitivity of TiAl to defects, a team consisting of GE Aircraft Engines, Precision Cast Parts, and NASA was formed. The work at the NASA Glenn Research Center at Lewis Field has concentrated on the fatigue response to specimens containing defects. The overall objective of this work is to determine the influence of defects on the high cycle fatigue life of TiAl-simulated low-pressure turbine blades. Two types of defects have been introduced into the specimens: cracking from impact damage and casting porosity. For both types of defects, the cast-to-size fatigue specimens were fatigue tested at 650 C and 100 Hz until failure.

Lerch, Bradley A.↗

NASA NTRS1999

Cyclic Oxidation of FeCrAlY/Al2O3 Composites

Three-ply FeCrAlY/Al2O3 composites and FeCrAlY matrix-only samples were cyclically oxidized at 1000 C and 1100 C for up to 1000 1-hr cycles. Fiber ends were exposed at the ends of the composite samples. Following cyclic oxidation, cracks running parallel to and perpendicular to the fibers were observed on the large surface of the composite. In addition, there was evidence of increased scale damage and spallation around the exposed fiber ends, particularly around the middle ply fibers. This damage was more pronounced at the higher temperature. The exposed fiber ends showed cracking between fibers in the outer plies, occasionally with Fe and Cr-rich oxides growing out of the cracks. Large gaps developed at the fiber/matrix interface around many of the fibers, especially those in the outer plies. Oxygen penetrated many of these gaps resulting in significant oxide formation at the fiber/matrix interface far within the composite sample. Around several fibers, the matrix was also internally oxidized showing Al2O3 precipitates in a radial band around the fibers. The results show that these composites have poor cyclic oxidation resistance due to the CTE mismatch and inadequate fiber/matrix bond strength at temperatures of 1000 C and above.

Nesbitt, James A.↗

NASA NTRS1999

Resistance of Titanium Aluminide to Domestic Object Damage Assessed

A team consisting of GE Aircraft Engines, Precision Cast Parts, Oremet, and Chromalloy were awarded a NASA-sponsored Aerospace Industry Technology Program (AITP) to develop a design and manufacturing capability that will lead to the engine test demonstration and eventual implementation of a ?-Ti-47Al-2Nb-2Cr (at. %) titanium aluminide (TiAl) low-pressure turbine blade into commercial service. One of the main technical risks of implementing TiAl low-pressure turbine blades is the poor impact resistance of TiAl in comparison to the currently used nickel-based superalloy. The impact resistance of TiAl is being investigated at the NASA Lewis Research Center as part of the Aerospace Industry Technology Program and the Advanced High Temperature Engine Materials Program (HITEMP). The overall objective of this work is to determine the influence of impact damage on the high cycle fatigue life of TiAl-simulated low-pressure turbine blades. To this end, impact specimens were cast to size in a dog-bone configuration and given a typical processing sequence followed by an exposure to 650 degrees Celsius for 20 hours to simulate embrittlement at service conditions. Then, the specimens were impacted at 260 degrees Celsius under a 69-MPa load. Steel projectiles with diameters 1.6 and 3.2 mm were used to impact the specimens at 90 degrees Celsius to the leading edge. Two different impact energies (0.74 and 1.5 joules) were used to simulate fairly severe domestic object damage on a low-pressure turbine blade.

Lerch, Bradley A.↗

NASA NTRS1998

Effect of Composite Fabrication on the Strength of Single Crystal Al2O3 Fibers in Two Fe-Base Alloy Composites

Continuous single-crystal Al2O3 fibers have been incorporated into a variety of metal and intermetallic matrices and the results have consistently indicated that the fiber strength had been reduced by 32 to 50% during processing. Two iron-based alloys, FeNiCoCrAl and FeAlVCMn, were chosen as matrices for Al2O3 fiber reinforced metal matrix composites (MMC) with the goal of maintaining Al2O3 fiber strength after composite processing. The feasibility of Al2O3/FeNiCoCrAl and Al2O3/FeAlVCMn composite systems for high temperature applications were assessed in terms of fiber-matrix chemical compatibility, interfacial bond strength, and composite tensile properties. The strength of etched-out fibers was significantly improved by choosing matrices containing less reactive elements. The ultimate tensile strength (UTS) values of the composites could generally be predicted with existing models using the strength of etched-out fibers. However, the UTS of the composites were less than desired due to a low fiber Weibull modulus. Acoustic emission analysis during tensile testing was a useful tool for determining the efficiency of the fibers in the composite and for determining the failure mechanism of the composites.

Draper, Susan L.↗

NASA NTRS1989

Annealing group III-V compound doped silicon-germanium alloy for improved thermo-electric conversion efficiency

The thermoelectric conversion efficiency of a GaP doped SiGe alloy is improved about 30 percent by annealing the alloy at a temperature above the melting point of the alloy, preferably stepwise from 1200 C to 1275 C in air to form large grains having a size over 50 microns and to form a GeGaP rich phase and a silicon rich phase containing SiP and SiO2 particles.

Vandersande, Jan W.↗

NASA NTRS1988

Improved GaP doped SiGe thermoelectric material

Work at TECO has independently confirmed the early results obtained at JPL that high-temperature heat-treatment of SiGe/GaP alloys can significantly increase the figure of merit Z of these alloys. Several possible reasons for this improvement are given. Experiments are in progress to test these various hypothesis.

Vandersande, Jan W.↗

NASA NTRS1987

Effect of high-temperature annealing on the microstructure and thermoelectric properties of GaP doped SiGe

Annealing of GaP doped SiGe will significantly alter the thermoelectric properties of the material resulting in increased performance as measured by the figure of merit Z and the power factor P. The microstructures and corresponding thermoelectric properties after annealing in the 1100 to 1300 C temperature range have been examined to correlate performance improvement with annealing history. The figure of merit and power factor were both improved by homogenizing the material and limiting the amount of cross-doping. Annealing at 1215 C for 100 hr resulted in the best combination of thermoelectric properties with a resultant figure of merit exceeding 1x10 to the -3 deg C to the -1 and a power factor of 44 microW/cm/deg C sq for the temperature range of interest for space power: 400 to 1000 C.

Draper, Susan L.↗

NASA NTRS1987

Observations of directional gamma prime coarsening during engine operation

Two alloys with negative mismatch parameters, NASAIR 100 and a modified NASAIR 100 called Alloy 3 were run as turbine blades in an experimental ground based Garret TFE731 engine for up to 200 hr. The directional coarsening of gamma prime (rafting) that developed during engine testing was analyzed and compared to previous research from laboratory tests. The blades were found to be rafted normal to the centrifugal stress axis over much of the span, but near the surfaces, the blades were found to be rafted parallel to the centrifugal stress axis for certain cycles. Representative photomicrographs of the blades and the effects of stress and temperature on raft formation are shown.

Draper, Susan L.↗