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Sheffler, K. D.

Publications and source records attributed to Sheffler, K. D..

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

MATE (Materials for Advanced Turbine Engines) Program, Project 3. Volume 2: Design, fabrication and evaluation of an oxide dispersion strengthened sheet alloy combustor liner

The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Two yttria (Y2O3) dispersion strengthened alloys were evaluated; Incoloy MA956 and Haynes Development Alloy (HDA) 8077 (NiCrAl base). Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. MA956 was selected as the final alloy based on manufacturing reproducibility for evaluation as a burner liner. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components and using a louvered configuration was designed and constructed. The louvered configuration was chosen because of field experience and compatibility with the bill of material PW2037 design. The simulated flight cycle for the ground based engine tests consisted of 4.5 min idle, 1.5 min takeoff and intermediate conditions in a PW2037 engine with average uncorrected combustor exit temperature of 1527 C. Post test evaluation consisting of visual observations and fluorescent penetrant inspections was conducted after 500 cycles of testing. No loss of integrity in the burner liner was shown.

Bose, S.↗
NASA NTRS1987

Thermal barrier coating life prediction model development

The objectives of this program are to increase understanding of thermal barrier coating (TBC) degradation and failure modes, to generate quantitative ceramic failure life data under cyclic thermal conditions which simulate those encountered in gas turbine engine service, and to develop an analytical methodology for prediction of coating life in the engine. Observations of degradation and failure modes in plasma deposited ceramic indicate that spallation failure results from progressive cracking of the ceramic parallel to and adjacent to, but not coincident with the metal-ceramic interface.

Demasi, J. T.↗
NASA NTRS1986

Thermal barrier coating life prediction model development

The objective of this program is to establish a methodology to predict Thermal Barrier Coating (TBC) life on gas turbine engine components. The approach involves experimental life measurement coupled with analytical modeling of relevant degradation modes. The coating being studied is a flight qualified two layer system, designated PWA 264, consisting of a nominal ten mil layer of seven percent yttria partially stabilized zirconia plasma deposited over a nominal five mil layer of low pressure plasma deposited NiCoCrAlY. Thermal barrier coating degradation modes being investigated include: thermomechanical fatigue, oxidation, erosion, hot corrosion, and foreign object damage.

Demasi, J. T.↗
NASA NTRS1985

Thermal barrier coating life prediction model development

A methodology was established to predict thermal barrier coating life in an environment simulative of that experienced by gas turbine airfoils. Specifically, work is being conducted to determine failure modes of thermal barrier coatings in the aircraft engine environment. Analytical studies coupled with appropriate physical and mechanical property determinations are being employed to derive coating life prediction model(s) on the important failure mode(s). An initial review of experimental and flight service components indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the metal-ceramic interface. Initial results from a laboratory test program designed to study the influence of various driving forces such as temperature, thermal cycle frequency, environment, and coating thickness, on ceramic coating spalling life suggest that bond coat oxidation damage at the metal-ceramic interface contributes significantly to thermomechanical cracking in the ceramic layer. Low cycle rate furnace testing in air and in argon clearly shows a dramatic increase of spalling life in the non-oxidizing environments.

Sheffler, K. D.↗
NASA NTRS1985

Thermal barrier coating life prediction model development

The objective is to develop an integrated life prediction model accounting for all potential life-limiting thermal barrier coating (TBC) degradation and failure modes, including spallation resulting from cyclic thermal stress, oxidation degradation, hot corrosion, erosion and foreign object damage.

Demasi, J. T.↗
NASA NTRS1985

Mechanisms of thermal barrier coating degradation and failure

The objectives and initial results of a Thermal Barrier Coating (TBC) Life Prediction Model Development Program are described. The goals of this program are to: identify and understand TBC failure modes; generate quantitative TBC life data; and develop and verify a TBC life prediction model. The coating being studied is a two layer thermal barrier system incorporating a nominal ten mil outer layer of seven percent yttria partially stabilized zirconia plasma deposited over an inner layer of highly oxidation resistant low pressure plasma sprayed NiCrAlY bond coating. This coating currently is in flight service on turbine vane platforms in the JT-9D and PW2037 engines and is bill-of- material on turbine vane airfoils in the advanced PW4000 and IAE V2500 engines. Effort currently is in progress on the first task, which involves the identification and understanding of TBC failures. Five modes of coating damage were considered: thermomechanical ceramic failure; oxidative bond coat failure; hot corrosion; foreign object damage (FOD); and erosion.

Demasi, J. T.↗
NASA NTRS1984

Materials for Advanced Turbine Engines (MATE): Project 3: Design, fabrication and evaluation of an oxide dispersion strengthened sheet alloy combustor liner, volume 1

The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Incoloy MA 956 (FeCrAl base) and Haynes Developmental Alloy (HDA) 8077 (NiCrAl base) were evaluated. Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. Both alloys demonstrated a +167C (300 F) advantage of creep and oxidation resistance with no improvement in thermal fatigue capability compared to a current generation combustor alloy (Hastelloy X). MA956 alloy was selected for further demonstration because it exhibited better manufacturing reproducibility than HDA8077. Additional property tests were conducted on MA956. To accommodate the limited thermal fatigue capability of ODS alloys, two segmented, mechanically attached, low strain ODS combustor design concepts having predicted fatigue lives or = 10,000 engine cycles were identified. One of these was a relatively conventional louvered geometry, while the other involved a transpiration cooled configuration. A series of 10,000 cycle combustor rig tests on subscale MA956 and Hastelloy X combustor components showed no cracking, thereby confirming the beneficial effect of the segmented design on thermal fatigue capability. These tests also confirmed the superior oxidation and thermal distortion resistance of the ODS alloy. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components was designed and constructed.

Henricks, R. J.↗
NASA NTRS1983

Development of strain tolerant thermal barrier coating systems, tasks 1 - 3

Insulating ceramic thermal barrier coatings can reduce gas turbine airfoil metal temperatures as much as 170 C (about 300 F), providing fuel efficiency improvements greater than one percent and durability improvements of 2 to 3X. The objective was to increase the spalling resistance of zirconia based ceramic turbine coatings. To accomplish this, two baseline and 30 candidate duplex (layered MCrAlY/zirconia based ceramic) coatings were iteratively evaluated microstructurally and in four series of laboratory burner rig tests. This led to the selection of two candidate optimized 0.25 mm (0.010 inch) thick plasma sprayed partially stabilized zirconia ceramics containing six weight percent yttria and applied with two different sets of process parameters over a 0.13 mm (0.005 inch) thick low pressure chamber sprayed MCrAlY bond coat. Both of these coatings demonstrated at least 3X laboratory cyclic spalling life improvement over the baseline systems, as well as cyclic oxidation life equivalent to 15,000 commercial engine flight hours.

Anderson, N. P.↗
NASA NTRS1982

JT90 thermal barrier coated vanes

The technology of plasma sprayed thermal barrier coatings applied to turbine vane platforms in modern high temperature commercial engines was advanced to the point of demonstrated feasibility for application to commercial aircraft engines. The three thermal barrier coatings refined under this program are zirconia stabilized with twenty-one percent magnesia (21% MSZ), six percent yttria (6% YSZ), and twenty percent yttria (20% YSZ). Improvement in thermal cyclic endurance by a factor of 40 times was demonstrated in rig tests. A cooling system evolved during the program which featured air impingement cooling for the vane platforms rather than film cooling. The impingement cooling system, in combination with the thermal barrier coatings, reduced platform cooling air requirements by 44% relative to the current film cooling system. Improved durability and reduced cooling air requirements were demonstrated in rig and engine endurance tests. Two engine tests were conducted, one of 1000 cycles and the other of 1500 cycles. All three coatings applied to vanes fabricated with the final cooling system configuration completed the final 1500 cycle engine endurance test. Results of this test clearly demonstrated the durability of the 6% YSZ coating which was in very good condition after the test. The 21% MSZ and 20% YSZ coatings had numerous occurrences of significant spalling in the test.

Sheffler, K. D.↗
NASA NTRS1976

Stress analysis, thermomechanical fatique evaluation, and root subcomponent testing of gamma/gamma prime-delta eutectic alloy

Thermomechanical fatigue (TMF) and root subcomponent tensile, creep, and low cycle fatigue (LCF) tests were conducted to determine the capability of a fully lamellar directionally solidified eutectic alloy to sustain the airfoil thermal fatigue and root attachment loads anticipated in advanced, hollow, high work turbine blades. A three dimensional finite element elastic stress analysis was performed on typical advanced hollow eutectic airfoil and root-platform designs to determine appropriate conditions for these tests. Results of TMF tests conducted on longitudinal specimens (stress axis parallel to the solidification direction) containing a simulated leading edge cooling hole pattern indicated the longitudinal TMF properties to be more than adequate for the particular advanced hollow blade analyzed, with the strain range for a 10,000 cycle life being more than 50% above the maximum strain range calculated for the advanced hollow blade.

Sheffler, K. D.↗
NASA NTRS1976

Alloy and structural optimization of a directionally solidified lamellar eutectic alloy

Mechanical property characterization tests of a directionally solidified Ni-20 percent Cb-2.5 percent Al-6 percent Cr cellular eutectic turbine blade alloy demonstrated excellent long time creep stability and indicated intermediate temperature transverse tensile ductility and shear strength to be somewhat low for turbine blade applications. Alloy and structural optimization significantly improves these off-axis properties with no loss of longitudinal creep strength or stability. The optimized alloy-structure combination is a carbon modified Ni-20.1 percent Cb-2.5 percent Al-6.0 percent Cr-0.06 percent C composition processed under conditions producing plane front solidification and a fully-lamellar microstructure. With current processing technology, this alloy exhibits a creep-rupture advantage of 39 C over the best available nickel base superalloy, directionally solidified MAR M200+ Hf. While improved by about 20 percent, shear strength of the optimized alloy remains well below typical superalloy values.

Sheffler, K. D.↗
NASA NTRS1976

Vacuum thermal-mechanical fatigue behavior of two iron-base alloys

The present study extends the concept of in-phase grain boundary ratcheting to two iron-base alloys (Type 304 stainless steel and A286 alloy) and provides a clearer interpretation of out-of-phase grain boundary ratcheting effects observed in the A286 alloy which does not exhibit geometric instability. Elevated-temperature low-cycle thermal-mechanical fatigue tests in an ion-pumped ultrahigh vacuum chamber revealed significant effects of frequency and combined temperature-strain cycling on fatigue life. In-phase thermal cycling (tension at high temperature and compression at low temperature) caused large life reductions in both materials due to grain boundary cavitation caused by unreversed grain boundary sliding (grain boundary ratcheting). Out-of-phase thermal cycling (tension at low temperature and compression at high temperature) also caused large cyclic life reductions in both materials. In the A286 alloy, out-of-phase life reductions are attributed to compressive ratcheting.

Sheffler, K. D.↗
NASA NTRS1974

The partitioned strainrange fatigue behavior of coated and uncoated MAR-M-302 at 1000 C (1832 F) in ultrahigh vacuum

Elevated temperature (1000 C (1832 F)) vacuum fatigue tests have been conducted on uncoated and aluminide (PWA 45) coated cobalt-base MAR-M-302 alloy with the four different types of thermalmechanical reversed inelastic strain cycles (wave shapes) defined by the method of strainrange partitioning. Results of these tests indicated two major conclusions. First, there was no significant influence of the aluminide coating on the thermal-mechanical fatigue life of the MAR-M-302 alloy. Second, variations in the type of thermal-mechanical fatigue cycle applied caused significant variations of fatigue life for both coated and uncoated material. The longest lives were achieved with sigma sub pp type cycling, while the sigma sub cc cycle caused a reduction of fatigue life of about 1/2 order of magnitude with respect to the sigma sub pp life. The sigma sub cp type cycle caused a life reduction of between 1-1/2 and 2 orders of magnitude relative to the sigma sub pp life, while the sigma sub pc type cycle provided a fatigue life which appeared to be comparable to that generated by the sigma sub cc cycle.

Sheffler, K. D.↗
NASA NTRS1974

Effect of long-time, elevated-temperature exposures to vacuum and lithium on the properties of a tantalum alloy, T-111

The effect of long-term, elevated-temperature vacuum and lithium exposures on the mechanical properties of T-111 (Ta-8W-2Hf) is determined. Exposure conditions were for 1000 hours at 980 or 1315 C, 5000 hours at 1315 C, and a duplex temperature exposure of 1000 hours at 980 C plus 4000 hours at 1040 C. The exposures resulted in reduced tensile and creep strengths of the T-111 in the 900 to 1100 C temperature range where a dynamic strain-age-strengthening mechanism is operative in this alloy. This strength reduction was attributed to the depletion of oxygen from solid solution in this alloy.

Buzzard, R. J.↗
NASA NTRS1974

Vacuum thermal-mechanical fatigue testing of two iron base high temperature alloys

Ultrahigh vacuum elevated temperature low cycle fatigue and thermal fatigue tests of 304 stainless steel and A-286 alloy have shown significant effects of frequency and combined temperature-strain cycling on fatigue life. At constant temperature, the cyclic life of both alloys was lower at lower frequencies. Combined temperature-strain cycling reduced fatigue life with respect to isothermal life at the maximum temperature of the thermal cycle. Life reductions with in-phase thermal cycling (tension at high temperature, compression at low temperature) were attributed to grain boundary cavitation caused by unreversed tensile grain boundary sliding. The proposed mechanism for out-of-phase cavity generation involved accumulation of unreversed compressive grain boundary displacements which could not be geometrically accomodated by intragranular deformation in the low-ductility A-286 alloy.

Sheffler, K. D.↗
NASA NTRS1973

Generation of long time creep data on refractory alloys at elevated temperatures

Four separate studies of various aspects of the vacuum creep behavior of two tantalum alloys (T-111 and ASTAR 811C) and of pure CVD tungsten are reported. The first part of the program involved a study of the influence of high temperature pre-exposure to vacuum or to liquid lithium on the subsequent creep behavior T-111 alloy. Results of this study revealed significant effects of pre-exposure on the 1% creep life of T-111, with life reductions of about 3 orders of magnitude being observed in extreme cases. The second part of this study involved an investigation of the creep behavior of T-111 under conditions of continuously increasing stress and decreasing temperature which simulated the conditions anticipated in radioisotope capsule service. Results of this study showed that such test conditions produced a creep curve having a very unusual shape, and led to the identification of a new creep design parameter for this type of service. The third area of investigation was a study of the influence of heat treatment on the microstructure and creep behavior of ASTAR 811C. The fourth part of the program was directed toward a preliminary characterization of the 1% creep life of CVD tungsten as obtained from two different sources.

Sheffler, K. D.↗
NASA NTRS1973

Thermal fatigue behavior of T-111 and ASTAR 811C in ultrahigh vacuum

The thermal fatigue behavior of the tantalum alloys T-111 (Ta-8W-2Hf) and ASTAR 811C (Ta-8W-1Re-0.7Hf-0.025C) has been evaluated using completely reversed push-pull fatigue tests conducted in ultrahigh vacuum with independently programmed temperature and strain cycles. Test results showed that cycling of the test temperature simultaneously with the mechanical strain in most cases significantly reduced the cycles to failure of both alloys compared to isothermal testing. Notched specimens had reduced lives under isothermal conditions, but the presence of a notch or use of a 1-h holdtime provided only a small further decrease in life for the temperature cycled tests. Compressive stress at the maximum temperature produced longer lives than tensile stress. ASTAR 811C was more fatigue resistant than T-111 isothermally and did not have as great a decrease in life with thermal cycling. Results are analyzed by partition of plastic strains into creep and creep-independent components and considering where each component was active in the hysteresis cycle.

Sheffler, K. D.↗