Engineering topics

Stanford, Malcolm K.

Publications and source records attributed to Stanford, Malcolm K..

At least 19 records

NASA NTRS2020

Lot-to-lot Variability of BN Grades for Space Electric Propulsion Applications

Historically, several grades of hot pressed hexagonal boron nitride have been used for space electric propulsion applications. This study investigates the material properties of a selection of commercially available boron nitride grades including HP, M26, M, BNXX, and Shapal Hi-M. This work complements data which was presented at JANNAF 2018. The grades selected for this study are of interest because their available billet size is sufficient for space electric propulsion. This research investigates a range of material properties, tailored and focused on enhancing performance, reliability, and economics of electric propulsion thrusters. This work builds upon previous efforts by studying lot-to-lot variability of some of the properties of interest. Coefficient of friction, moisture absorption, moisture sensitivity, hot press directionality, flexural strength, compression strength, elastic modulus, thermal conductivity, thermal emissivity, thermal expansion, density, X-ray diffraction phase, microstructure, and chemical composition were all investigated across two lots of materials to help guide the selection of advanced ceramics. Variability between lots is the critical concern of the study.

Mackey, Jonathan A.↗

NASA NTRS2019

Hardness and Microstructure of Binary and Ternary Nitinol Compounds

The hardness and microstructure of twenty-six binary and ternary Nitinol compounds (Ni-Ti, Ni-Ti- Ta, Ni-Ti-Hf, and Ni-Ti-Zr) were studied. A small (50g) button of each compound was produced by vacuum arc melting (VAM). Each alloy was homogenized in vacuum for 48 hr followed by furnace cooling. Specimens from the buttons were then heat treated at 800, 900, 1000 or 1100 °C for 2 hr followed by water quenching. The hardness and microstructure of each specimen was compared to the baseline (55-Nitinol, 55 at.% Ni – 45 at.% Ti, after heat treatment at 900 °C). The results show that sixteen of the studied compounds had higher hardness values than the baseline material with relatively low levels of secondary phase precipitation. Moreover, five of these compounds had hardness values greater than or equal to approximately 660HV (≈58HRC) with essentially no property-degrading precipitation phases.

Stanford, Malcolm K.↗

NASA NTRS2018

Fractographic Analysis of 60-Nitinol Bearing Races

Fracture surfaces on a failed bearing race made from 60-Nitinol (60 wt% Ni - 40 wt% Ti) were analyzed. The bearing had experienced excessive localized heat due to an issue during machining that may have resulted in dimensional distortion. However, the classical fracture features that were identified by scanning electron microscopy and the fracture origins coincided with high concentrations of TiC-based contamination. Lessons learned for processing and quality control are discussed. An attempt to use x-ray diffraction to directly measure residual stresses imparted from the required heat treatment is also discussed.

intermetallics↗

NASA NTRS2018

Friction and Wear of Unlubricated NiTiHf with Nitriding Surface Treatments

The unlubricated friction and wear properties of the superelastic materials NiTi and NiTiHf, treated by either gas nitriding or plasma nitriding, have been investigated. Pin on disk testing of the studied materials was performed at sliding speeds from 0.01 to 1m/s at normal loads of 1, 5 or 10N. For all of the studied friction pairs (NiTiHf pins vs. NiTi and NiTiHf disks) over the given parameters, the steady-state coefficients of friction varied from 0.22 to 1.6. Pin wear factors ranged from approximately 1E-6 against the NiTiHf and plasma nitrided disks to approximately 1E-4 for the gas nitrided disks. The plasma nitrided disks provided wear protection in several cases and tended to wear by adhesion. The gas nitrided treatment generated the most pin wear but had essentially no disk wear except at the most severe of the studied conditions (1N load and 1m/s sliding speed). The results of this study are expected to provide guidance for design of components such as gears and fasteners.

friction↗

NASA NTRS2017

Microstructural and Material Quality Effects on Rolling Contact Fatigue of Highly Elastic Intermetallic NiTi Ball Bearings

Rolling element bearings made from highly-elastic intermetallic materials (HIM)s, such as 60NiTi, are under development for applications that require superior corrosion and shock resistance. Compared to steel, intermetallics have been shown to have much lower rolling contact fatigue (RCF) stress capability in simplified 3-ball on rod (ASTM STP 771) fatigue tests. In the 3-ball tests, poor material quality and microstructural flaws negatively affect fatigue life but such relationships have not been established for full-scale 60NiTi bearings. In this paper, 3-ball-on-rod fatigue behavior of two quality grades of 60NiTi are compared to the fatigue life of full-scale 50mm bore ball bearings made from the same materials. 60NiTi RCF rods with material or microstructural flaws suffered from infant mortality failures at all tested stress levels while high quality 60NiTi rods exhibited no failures at lower stress levels. Similarly, tests of full-scale bearings made from flawed materials exhibited early surface fatigue and through crack type failures while bearings made from high quality material did not fail even in long-term tests. Though the full-scale bearing test data is yet preliminary, the results suggest that the simplified RCF test is a good qualitative predictor of bearing performance. These results provide guidance for materials development and to establish minimum quality levels required for successful bearing operation and life.

metals↗

NASA NTRS2017

Hardness and Second Phase Percentage of Ni-Ti-Hf Compounds After Heat Treatment at 700C

The Vickers hardness and second phase precipitation of three ternary intermetallic Ni-Ti-Hf compounds containing either 1, 3 or 5 at.% Hf were compared to 60-Nitinol (55 at.% Ni - 45 at.% Ti). Heat treatment either at 700 C or with a subsequent aging step, hardened the 3 and 5 at.% Hf-containing ternaries to approximately 620 HV (56 HRC). Heat treatment increased the hardness of the 1 at.% Hf compound by more than 25 percent. Average hardness of the 3 and 5 at.% Hf ternaries, though higher than that of the binary Ni-Ti or the Ni-Ti-Hf compound containing 1 at.% Hf, appeared to be fairly insensitive to the different heat treatments. There was a drastic reduction of fatigue-enhancing second phase precipitates for the 5 at.% Hf ternaries compared to the other compounds. These results should guide materials selection for development of aerospace componentry.

intermetallics↗

NASA NTRS2016

Preliminary Investigation of Surface Treatments to Enhance the Wear Resistance of 60-Nitinol

The use of protective surface treatments on 60-Nitinol (60wt%Ni-40wt%Ti) was studied. Various nitriding techniques as well as a (Ti, Al)N coating were evaluated visually, microscopically, and by hardness and scratch testing. The chemical composition of the surface treatments was investigated by x-ray techniques. The results indicate that very hard (greater than 1,000 HK) and adherent surface layers can be produced on 60-Nitinol. Further work is needed to determine the tribological properties of these surface treatments in relevant operating environments.

Nitinol↗

NASA NTRS2016

Microstructural and Material Quality Effects on Rolling Contact Fatigue of Highly Elastic Intermetallic Ball Bearings

tribology↗

NASA NTRS2016

Hardness and Microstructure of Binary and Ternary Nitinol Compounds

The hardness and microstructure of twenty-six binary and ternary Nitinol (nickel titanium, nickel titanium hafnium, nickel titanium zirconium and nickel titanium tantalum) compounds were studied. A small (50g) ingot of each compound was produced by vacuum arc remelting. Each ingot was homogenized in vacuum for 48 hr followed by furnace cooling. Specimens from the ingots were then heat treated at 800, 900, 1000 or 1100 degree C for 2 hr followed by water quenching. The hardness and microstructure of each specimen was compared to the baseline material (55-Nitinol, 55 at.% nickel - 45 at.% titanium, after heat treatment at 900 degC). The results show that eleven of the studied compounds had higher hardness values than the baseline material. Moreover, twelve of the studied compounds had measured hardness values greater 600HV at heat treatments from 800 to 900 degree C.

intermetallics↗

NASA NTRS2015

Mechanical Components from Highly Recoverable, Low Apparent Modulus Materials

A material for use as a mechanical component is formed of a superelastic intermetallic material having a low apparent modulus and a high hardness. The superelastic intermetallic material is conditioned to be dimensionally stable, devoid of any shape memory effect and have a stable superelastic response without irrecoverable deformation while exhibiting strains of at least 3%. The method of conditioning the superelastic intermetallic material is described. Another embodiment relates to lightweight materials known as ordered intermetallics that perform well in sliding wear applications using conventional liquid lubricants and are therefore suitable for resilient, high performance mechanical components such as gears and bearings.

Padula, Santo, II↗

NASA NTRS2012

Thermophysical Properties of 60-NITINOL for Mechanical Component Applications

The linear thermal expansion coefficient, specific heat capacity, electrical resistivity and thermal conductivity of 60- NITINOL were studied over a range of temperatures representing the operating environment of an oil-lubricated bearing. The behavior of this material appears to follow wellestablished theories applicable to either metal alloys, in general, or to intermetallic compounds, more specifically and the measured data were found to be comparable to those for conventional bearing alloys.

Stanford, Malcolm K.↗

NASA NTRS2012

Processing Issues for Preliminary Melts of the Intermetallic Compound 60-NITINOL

The effect of various high temperature heat treatments and cooling rates on the hardness of cast 60-NITINOL (60wt%Ni- 40wt%Ti) was studied. The hardness ranged from approximately 33 HRC for annealed specimens to 63 HRC for water quenched specimens. Aging did not have a further effect on the hardness of the heat-treated and quenched material. The issue of material contamination and its possible effect on quench cracking during heat treatment above 1000 C was explored. The Charpy impact energy of the material was found to be relatively low (ranging from 0.4 to 1.0 J) and comparable to that of cast magnesium. Selection of service environments and applications for this material based on these findings should consider the processing route by which it was produced.

Stanford, Malcolm K.↗

NASA NTRS2012

Charpy Impact Energy and Microindentation Hardness of 60-NITINOL

60-NITINOL (60 wt.% Ni 40 wt.% Ti) is being studied as a material for advanced aerospace components. The Charpy impact energy and microindentation hardness has been studied for this material, fabricated by vacuum induction skull melting (casting) and by hot isostatic pressing. Test specimens were prepared in various hardened and annealed heat treatment conditions. The average impact energy ranged from 0.33 to 0.49J for the hardened specimens while the annealed specimens had impact energies ranging from 0.89 to 1.18J. The average hardness values of the hardened specimens ranged from 590 to 676 HV while that of the annealed specimens ranged from 298 to 366 HV, suggesting an inverse relationship between impact energy and hardness. These results are expected to provide guidance in the selection of heat treatment processes for the design of mechanical components.

Stanford, Malcolm K.↗

NASA NTRS2012

Addressing Machining Issues for the Intermetallic Compound 60-NITINOL

60-NITINOL (60 wt.% Ni - 40 wt.% Ti) is being studied as a material for advanced aerospace components. Frequent wire breakage during electrical-discharge machining of this material was investigated. The studied material was fabricated from hot isostatically pressed 60-NITINOL powder obtained through a commercial source. Bulk chemical analysis of the material showed that the composition was nominal but had relatively high levels of certain impurities, including Al and O. It was later determined that Al2O3 particles had contaminated the material during the hot isostatic pressing procedure and that these particles were the most likely cause of the wire breakage. The results of this investigation highlight the importance of material cleanliness to its further implementation.

Stanford, Malcolm K.↗

NASA NTRS2012

Promoted-Ignition Testing to Determine the Gaseous Oxygen Compatibility of the Intermetallic Compound 60-NITINOL

The flammability of 60-NITINOL (60 weight percentage Ni and 40 weight percentage Ti) in an oxygen-rich atmosphere is assessed. It is determined that 60-NITINOL burns readily in gaseous oxygen and would not be a good candidate for components exposed to oxygen-rich environments where there may be an ignition source. The results are the same whether the material is tested without heat treatment, after a solution treatment or after furnace annealing. These results provide guidance for materials selection of aerospace turbomachinery components.

intermetallics↗

NASA NTRS2008

Atomized BaF2-CaF7 for Better-Flowing Plasma-Spray Feedstock

Atomization of a molten mixture of BaF2 and CaF2 has been found to be superior to crushing of bulk solid BaF2- CaF2 as a means of producing eutectic BaF2-CaF2 powder for use as an ingredient of the powder feedstock of a high-temperature solid lubricant material known as PS304. Developed to reduce friction and wear in turbomachines that incorporate foil air bearings, PS304 is applied to metal substrates by plasma spraying. The constituents of PS304 are: a) An alloy of 80 weight percent Ni and 20 weight percent Cr, b) Cr2O3, c) Ag, and d) The BaF2-CaF2 eutectic, specifically, 62 weight percent BaF2 and 38 weight percent CaF2. The superiority of atomization as a means of producing the eutectic BaF2-CaF2 powder lies in (1) the shapes of the BaF2-CaF2 particles produced and (2) the resulting flow properties of the PS304 feedstock powder: The particles produced through crushing are angular, whereas those produced through atomization are more rounded. PS304 feedstock powder containing the more rounded BaF2-CaF2 particles flows more freely and more predictably, as is preferable for plasma spraying.

DellaCorte, Christopher↗

NASA NTRS2007

Tribological Performance of PM300 Solid Lubricant Bushings for High Temperature Applications

PM300 is a high temperature solid lubricant material produced through conventional powder metallurgy processing. PM300 is a combination of metal binder (NiCr), hardener (Cr2O3) and lubricant (Ag and BaF2/CaF2) phases and is in commercial use in high temperature furnace conveyors. In this paper, the tribological characteristics of PM300 are evaluated using a newly developed bushing test rig in which PM300 bushings are loaded against rotating steel shafts at temperatures from 25 to 650 C. The data shows that friction and wear are low to moderate and that the lubrication performance (friction) improves with increasing temperature. Several alternative PM300 compositions are evaluated which do not contain silver and are targeted at aircraft gas turbine applications in which environmental compatibility of silver is a concern. It is expected that the data resulting from this research will further the commercialization of this technology.

Striebing, Donald R.↗

NASA NTRS2007

A Review of Tribomaterial Technology for Space Nuclear Power Systems

The National Aeronautics and Space Administration (NASA) has recently proposed a nuclear closed-cycle electric power conversion system for generation of 100-kW of electrical power for space exploration missions. A critical issue is the tribological performance of sliding components within the power conversion unit that will be exposed to neutron radiation. This paper presents a review of the main considerations that have been made in the selection of solid lubricants for similar applications in the past as well as a recommendations for continuing development of the technology.

Stanford, Malcolm K.↗