New weldable high-strength aluminum alloys for cryogenic service.
High strength weldable Al alloys with good cryogenic toughness, stress-corrosion cracking resistance and tensile strength
ALUMINUM ALLOY↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Comparative cut-bar thermal conductivity apparatus.
Construction details, error analysis, and typical data for a rapid comparative device for thermal conductivity measurements are presented. The apparatus consists of a comparative cut-bar arrangement contained in a bell-jar. The cylinder shaped specimen is placed between two ARMCO-iron meter bars of the same diameter. The upper bar is equipped with a heater, while the lower one is terminated in a heat sink. The temperature gradient along the bars is measured with a series of copper/constantan microthermocouples, spot welded to them. The assembly is held together by loading the bars to a desired pressure, via a pneumatic cylinder. Contact resistance at the boundaries between the specimen and the meter bars is minimized by using a Hg/In/Ga alloy film at the interface and sufficient loading force. The gradients determined for the meter bars then may be extrapolated to the boundaries yielding the temperature drop along the specimen. Using two different length specimens, the magnitude of the temperature drop across the interface can be computed, or the true gradient along the specimen can be obtained from the difference in overall temperature drops and lengths.
Gaal, P. S.↗
Testing of brazed and welded connections of stainless-steel tubing
Test procedures and results are given for three types of semipermanent sleeve-type connections for stainless-steel tubing. Subject to the limited resistances to corrosion and vibration, all three types are found to be suitable for extremes in reliability and environment, if given close control during manufacture.
Cahill, J. B.↗
Controlled ferrite content improves weldability of corrosion-resistant steel
Corrosion-resistant steel that adds restrictions on chemical composition to ensure sufficient ferrite content decreases the tendency of CRES to develop cracks during welding. The equations restricting composition are based on the Schaeffler constitution diagram.
Malin, C. O.↗
Nondestructive testing of electro thermal devices
This paper describes the results of a recent investigation into 'thermal time constant' nondestructive testing of high reliability electrical fuses. The use of established nondestructive test technology for examining the quality and firing characteristics of electro-explosive devices has been successfully applied to the inspection and prediction of the functional performance of electrical fuses. The technique requires application of a low level current pulse to the electrical fuse with an oscilloscope display of the curve as generated by the temperature coefficient of resistance feedback. The heating curve of temperature vs time is composed of one predominant thermal time constant, which is the product of the test unit's thermal capacity and thermal resistance. It has been found that the quality of the individual electrical fuse, for instance, the relative condition of the critical internal weld or solder joint, can be examined nondestructively.
Earnest, J. E., Jr.↗
Bonding titanium to Rene 41 alloy
Pair of intermediate materials joined by electron beam welding method welds titanium to Rene 41 alloy. Bond is necessary for combining into one structure high strength-to-density ratio titanium fan blades and temperature resistant nickel-base alloy turbine-buckets in VTOL aircraft lift-fan rotor.
Scott, R. W.↗
Enhanced Eddy-Current Detection Of Weld Flaws
Mixing of impedances measured at different frequencies reduces noise and helps reveal flaws. In new method, one excites eddy-current probe simultaneously at two different frequencies; usually, one of which integral multiple of other. Resistive and reactive components of impedance of eddy-current probe measured at two frequencies, mixed in computer, and displayed in real time on video terminal of computer. Mixing of measurements obtained at two different frequencies often "cleans up" displayed signal in situations in which band-pass filtering alone cannot: mixing removes most noise, and displayed signal resolves flaws well.
Van Wyk, Lisa M.↗
Diamond-Coated Wire-Feeding Nozzle
Hard vacuum-deposited film improves nozzle properties. Tip and bore surfaces of proposed nozzle for feeding wire for gas/tungsten arc welding coated with film of synthetic diamond. Film gives nozzle following advantages: lower friction, thermal conductivity, less wear, electrical isolation of wire from nozzle, and high resistance to corrosion.
Gilbert, Jeffrey L.↗
Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge
Bulk metallic glasses (BMGs), a class of amorphous metals defined as having a thickness greater than 1 mm, are being broadly investigated by NASA for use in spacecraft hardware. Their unique properties, attained from their non-crystalline structure, motivate several game-changing aerospace applications. BMGs have low melting temperatures so they can be cheaply and repeatedly cast into complex net shapes, such as mirrors or electronic casings. They are extremely strong and wear-resistant, which motivates their use in gears and bearings. Amorphous metal coatings are hard, corrosion-resistant, and have high reflectivity. BMG composites, reinforced with soft second phases, can be fabricated into energy-absorbing cellular panels for orbital debris shielding. One limitation of BMG materials is their inability to be welded, bonded, brazed, or fastened in a convenient method to form larger structures. Cellular structures (which can be classified as trusses, foams, honeycombs, egg boxes, etc.) are useful for many NASA, commercial, and military aerospace applications, including low-density paneling and shields. Although conventional cellular structures exhibit high specific strength, their porous structures make them challenging to fabricate. In particular, metal cellular structures are extremely difficult to fabricate due to their high processing temperatures. Aluminum honeycomb sandwich panels, for example, are used widely as spacecraft shields due to their low density and ease of fabrication, but suffer from low strength. A desirable metal cellular structure is one with high strength, combined with low density and simple fabrication. The thermoplastic joining process described here allows for the fabrication of monolithic BMG truss-like structures that are 90% porous and have no heat-affected zone, weld, bond, or braze. This is accomplished by welding the nodes of stacked BMG composite panels using a localized capacitor discharge, forming a single monolithic structure. This removes many complicated and costly fabrication steps. Moreover, the cellular structures detailed in this work are among the highest- strength and most energy-absorbent materials known. This implies that a fabricated structure made from these materials would have unequaled mechanical properties compared to other metal foams or trusses. The process works by taking advantage of the electrical properties of the matrix material in the metal-matrix composite, which in this case is a metallic glass. Due to the random nanoscale arrangement of atoms (without any grain boundaries), the matrix glass exhibits a near-constant electrical resistivity as a function of temperature. By placing the composite panels between two copper electrode plates and discharging a capacitor, the entire matrix of the panel can be heated to approximately 700 C in 10 milliseconds, which is above the alloy s solidus but below the liquidus. By designing the geometry of the panels into the shape of an egg box, the electrical discharge localizes only in the tips of each pyramidal cell. By applying a forging load during discharge, the nodes of the panels can be fused together into a single piece, which then dissipates heat through radiation back into a glassy state. This means that two panels can be metallurgically fused into one panel with no heat-affected zone, creating a seamless connection between panels. During the process, the soft metal particles (dendrites) that are uniformly distributed in the glassy matrix to increase the toughness are completely unaffected by the thermoplastic joining. The novelty is that a truss (or foam-like) structure can be formed with excellent energy- absorbing capabilities without the need for machining. The technique allows for large-scale fabrication of panels, well-suited for spacecraft shields or military vehicle door panels. Crystalline metal cellular structures cannot be fabricated using the thermoplastic joining technique described here. If metal panels were te assembled into a cellular structure, they would either have to be welded, brazed, bonded, or fastened together, creating a weak spot in the structure at each connection. Welded parts require a welding material to be added to the joint and exhibit a soft and weak heat-affected zone. Brazing and bonding do not form a metallurgical joint and thus exhibit low strengths, especially when the panels are pulled apart and fasteners require high-stress-concentration holes to be drilled. No equivalent rapid heating method exists for assembling metal panels together into cellular structures, and thus, those parts must be foamed, machined, or investment cast if they are to form a monolithic structure. If the crystalline panels were to be joined using capacitive discharge, as with a spot welder, their bond would be very weak, and the panels would have to be extremely thin. In contrast, the strength of joined BMG parts has been demonstrated to have strength comparable to the parent material. This technique opens up the possibility of using large-scale BMG hardware in spacecraft, military, or commercial applications.
Hofmann, Douglas C.↗
Development of strain gages for use to 1311 K (1900 F)
A high temperature electric resistance strain gage system was developed and evaluated to 1366 K (2000 F) for periods of at least one hour. Wire fabricated from a special high temperature strain gage alloy (BCL-3), was used to fabricate the gages. Various joining techniques (NASA butt welding, pulse arc, plasma needle arc, and dc parallel gap welding) were investigated for joining gage filaments to each other, gage filaments to lead-tab ribbons, and lead-tab ribbons to lead wires. The effectiveness of a clad-wire concept as a means of minimizing apparent strain of BCL-3 strain gages was investigated by sputtering platinum coatings of varying thicknesses on wire samples and establishing the optimum coating thickness--in terms of minimum resistivity changes with temperature. Finally, the moisture-proofing effectiveness of barrier coatings subjected to elevated temperatures was studied, and one commercial barrier coating (BLH Barrier H Waterproofing) was evaluated.
Lemcoe, M. M.↗
Effect of chloride contamination in MON-1 propellant on crack growth properties of metals
The effect of a high level of chloride content (800 ppm) in MON-1 propellant on the crack growth properties of seven materials was investigated. Sustained load tests were conducted at 49 C (120 F) temperature with thin gauge tensile specimens having a semi-elliptical surface flaw. Alloys included aluminum 1100, 3003, 5086 and 6061; corrosion resistant steel types A286 and 347; and titanium 6Al-4V. The configurations tested with precracked flaws exposed to MON-1 were: parent or base metal, center weld, and heat affected zone. It was concluded that this chloride level in MON-1 does not affect the stress corrosion, crack growth properties of these alloys after 1000 hour exposure duration under high stresses.
Moran, C. M.↗
Quick-Disconnect Fastener
Proposed quick-disconnect fastener for two or more parts resists shear loads and torque. Device centers parts to be joined, clamps and tightens them into single unit. Potential applications for removable fastener include holding parts for welding, brazing, soldering, riveting, and gluing. Other possible uses are for attaching removable panels and panels with poor access on one side and plugging leaks in pressure vessels.
Palmer, L. W.↗
Compatibility Studies of Hydrogen Peroxide and a New Hypergolic Fuel Blend
Several preliminary materials compatibility studies have been conducted to determine the practicality of a new hypergolic fuel system. Hypergolic fuel ignites spontaneously as the oxidizer decomposes and releases energy in the presence of the fuel. The bipropellant system tested consists of high-test hydrogen peroxide (HTP) and a liquid fuel blend consisting of a hydrocarbon fuel, an ignition enhancer and a transition metal catalyst. In order for further testing of the new fuel blend to take place, some basic materials compatibility and HTP decomposition studies must be accomplished. The thermal decomposition rate of HTP was tested using gas evolution and isothermal microcalorimetry (IMC). Materials were analyzed for compatibility with hydrogen peroxide including a study of the affect welding has on stainless steel elemental composition and its relation to HTP decomposition. Compatibility studies of valve materials in the fuel blend were performed to determine the corrosion resistance of the materials.
Baldridge, Jennifer↗
Generation of sonic power during welding
Generation of intense sonic and ultrasonic power in the weld zone, close to the puddle, reduces the porosity and refinement of the grain. The ac induction brazing power supply is modified with long cables for deliberate addition of resistance to that circuit. The concept is extensible to the molding of metals and plastics.
Mc Campbell, W. M.↗
Palladium-chromium static strain gages for high temperatures
An electrical resistance strain gage that can provide accurate static strain measurement to a temperature of 1500 F or above is being developed both in fine wire and thin film forms. The gage is designed to be temperature compensated on any substrate material. It has a dual element: the gage element is a special alloy, palladium-13wt percent chromium (PdCr), and the compensator element is platinum (Pt). Earlier results of a PdCr based wire gage indicated that the apparent strain of this gage can be minimized and the repeatability of the apparent strain can be improved by prestabilizing the gage on the substrate for a long period of time. However, this kind of prestabilization is not practical in many applications and therefore the development of a wire gage which is prestabilized before installation on the substrate is desirable. This paper will present our recent progress in the development of a prestabilized wire gage which can provide meaningful strain data for the first thermal cycle. A weldable PdCr gage is also being developed for field testing where conventional flame-spraying installation can not be applied. This weldable gage is narrower than a previously reported gage, thereby allowing the gage to be more resistant to buckling under compressive loads. Some preliminary results of a prestabilized wire gage flame-sprayed directly on IN100, an engine material, and a weldable gage spot-welded on IN100 and SCS-6/(beta)21-S Titanium Matrix Composite (TMC), a National Aero-Space Plane (NASP) structure material, will be reported. Progress on the development of a weldable thin film gage will also be addressed. The measurement technique and procedures and the lead wire effect will be discussed.
Lei, Jih-Fen↗
Advances in Solid State Joining of Haynes 230 High Temperature Alloy
The J-2X engine is being designed for NASA s new class of crew and launch vehicles, the Ares I and Ares V. The J-2X is a LOX/Hydrogen upper stage engine with 294,000 lbs of thrust and a minimum Isp of 448 seconds. As part of the design criteria to meet the performance requirements a large film-cooled nozzle extension is being designed to further expand the hot gases and increases the specific impulse. The nozzle extension is designed using Haynes 230, a nickel-chromium-tungsten-molybdenum superalloy. The alloy was selected for its high strength at elevated temperatures and resistance to hydrogen embrittlement. The nozzle extension is manufactured from Haynes 230 plate spun-forged to form the contour and chemically-milled pockets for weight reduction. Currently fusion welding is being evaluated for joining the panels which are then mechanically etched and thinned to required dimensions for the nozzle extension blank. This blank is then spun formed into the parabolic geometry required for the nozzle. After forming the nozzle extension, weight reduction pockets are chemically milled into the nozzle. Fusion welding of Haynes results in columnar grains which are prone to hot cracking during forming processes. This restricts the ability to use spin forging to produce the nozzle contour. Solid state joining processes are being pursued as an alternative process to produce a structure more amenable to spin forming. Solid state processes have been shown to produce a refined grain structure within the joint regions as illustrated in Figure 1. Solid state joining processes include friction stir welding (FSW) and a patented modification termed thermal stir welding (TSW). The configuration of TSWing utilizes an induction coil to preheat the material minimizing the burden on the weld tool extending its life. This provides the ability to precisely select and control the temperature. The work presented in this presentation investigates the feasibility of joining the Haynes 230 alloy using the solid state welding processes of FSW and TSW. Process descriptions and attributes of each weld process will be presented. Weld process set-up and welding techniques will be discussed leading to the challenges experienced in joining the superalloy. Mechanical property data will also be presented.
Ding, R. Jeffrey↗
Development of a High Performance, Low Profile Translation Table with Wire Feedthrough for a Deep Space CubeSat
NEAScout, a 6U cubesat and secondary payload on NASA's EM-1, will use an 85 sq m solar sail to travel to a near-earth asteroid at about 1 Astronomical Unit (about 1.5 x 10(exp 8) km) for observation and reconnaissance1. A combination of reaction wheels, reaction control system, and a slow rotisserie roll about the solar sail's normal axis were expected to handle attitude control and adjust for imperfections in the deployed sail during the 2.5-year mission. As the design for NEAScout matured, one of the critical design parameters, the offset in the center of mass and center of pressure (CP/CM offset), proved to be sub-optimal. After significant mission and control analysis, the CP/CM offset was accommodated by the addition of a new subsystem to NEAScout. This system, called the Active Mass Translator (AMT), would reside near the geometric center of NEAScout and adjust the CM by moving one portion of the flight system relative to the other. The AMT was given limited design space - 17 mm of the vehicle's assembly height-and was required to generate +/-8 cm by +/-2 cm translation to sub-millimeter accuracy. Furthermore, the design must accommodate a large wire bundle of small gage, single strand wire and coax cables fed through the center of the mechanism. The bend radius, bend resistance, and the exposure to deep space environment complicates the AMT design and operation and necessitated a unique design to mitigate risks of wire bundle damage, binding, and cold-welding during operation. This paper will outline the design constraints for the AMT, discuss the methods and reasoning for design, and identify the lessons learned through the designing, breadboarding and testing for the low-profile translation stages with wire feedthrough capability.
Few, Alex↗
Development of a High Performance, Low-Profile Translation Table with Wire Feedthrough
NEAScout, a 6U cubesat, will use an 85 sq m solar sail to travel to a near-earth asteroid for observation. Over the course of the 3-year mission, a combination of reaction wheels, cold gas reaction control system, and a slow rotisserie roll about the solar sail's normal axis were expected to handle attitude control and adjust for imperfections in the deployed sail. As the design for NEAScout matured, one of the critical design parameters, the offset in the center of mass and center of pressure (CP/CM offset), proved to be sub-optimal. After significant mission and control analysis, the CP/CM offset was addressed and a new subsystem was introduced to NEAScout. This system, called the Active Mass Translator (AMT), would reside near the geometric center of NEAScout and adjust the CM by moving one portion of the flight system relative to the other. The AMT was given limited design space-about 17 mm of the vehicle's assembly height-and was required to generate +/-10 cm by +/-5 cm translation to sub-millimeter accuracy. Furthermore, the design must accommodate a large wire bundle of small gage, single strand wire and coax cables fed through the center of the mechanism. The bend radius, bend resistance, and the exposure to deep space environment complicates the AMT design and operation and necessitated a unique design to mitigate risks of wire bundle damage, binding, and cold-welding during operation. This paper will outline the design constraints for the AMT, discuss the methods and reasoning for design, and identify the lessons learned through the design downselect process and breadboarding for designing low-profile translation stages with feedthrough capabilities.
Few, Alex↗