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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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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Characterization of SiC/SiC Composites Subjected to Sequential Tensile Creep and Dwell Fatigue in Air under Thermal Gradient Conditions

Uncoated SiC/SiC composites, with 2D and 3D fiber architectures, were investigated under steady state thermal gradient conditions with sequential tensile creep and dwell fatigue. Melt infiltration (MI), chemical vapor infiltration (CVI), polymer impregnation and pyrolysis (PIP), and hybrid (CVI and PIP) techniques were used to fabricate ceramic matrix composites (CMCs) with a 2D balanced fiber architecture. CMCs with 3D fiber weaves were also fabricated using MI and hybrid methods. Steady state through the thickness thermal gradients were generated for the tensile specimens using laser heating on the front (hot side) and forced air cooling on the back (cold side). Hot side and cold side temperatures of 2400 and 2200 °F, respectively, were used for testing CMCs fabricated with the MI process, whereas hot side and cold side temperatures of 2700 and 2400 °F, respectively, were used for CMCs fabricated with CVI, PIP, and hybrid processes. Each CMC specimen was initially tested under tensile creep at 69 MPa (10 ksi) for 80 hours, which was then followed by tensile dwell fatigue testing at a maximum stress of 69 MPa (10 ksi) for another 80 hours for a total of 160 hours. This type of sequential tensile creep followed by tensile dwell fatigue testing was performed to ascertain the integrity of uncoated CMCs under steady state thermal gradient conditions. Tensile creep and dwell fatigue test results, generated under steady state thermal gradient conditions on different types of SiC/SiC composites, are compared with corresponding creep behaviors observed under isothermal conditions to determine the influence of both monotonic creep (static fatigue) and dwell fatigue on accumulated strains and deformation behaviors of the CMCs.

Kalluri, Sreeramesh↗
NASA NTRS1973

High temperature, low-cycle fatigue of copper-base alloys in argon. Part 2: Zirconium-copper at 482, 538 and 593 C

Zirconium-copper (1/2 hard) was tested in argon over the temperature range from 482 to 593 C in an evaluation of short-term tensile and low-cycle fatigue behavior. The effect of strain rate on the tensile properties was evaluated at 538 C and in general it was found that the yield and ultimate strengths increased as the strain rate was increased from 0.0004 to 0.01/sec. Ductility was essentially insensitive to strain rate in the case of the zirconium-copper alloy. Strain-rate and hold-time effects on the low cycle fatigue behavior of zirconium-copper were evaluated in argon at 538 C. These effects were as expected in that decreased fatigue life was noted as the strain rate decreased and when hold times were introduced into the tension portion of the strain-cycle. Hold times in compression were much less detrimental than hold times in tension.

Conway, J. B.↗
NASA NTRS1976

Ultrahigh vacuum, high temperature, low cycle fatigue of coated and uncoated Rene 80

A study was conducted on the ultrahigh vacuum strain controlled by low cycle fatigue behavior of uncoated and CODEP B-1 aluminide coated Rene' 80 nickel-base superalloy at 1000 C (1832 F) and 871 C (1600 F). The results indicated little effect of coating or temperature on the fatigue properties. There was, however, a significant effect on fatigue life when creep was introduced into the strain cycles. The effect of this creep component was analyzed in terms of the method of strainrange partitioning.

Kortovich, C. S.↗
NASA NTRS1988

Bithermal fatigue: A simplified alternative to thermomechanical fatigue

A bithermal fatigue test technique was proposed as a simplified alternative to the thermomechanical fatigue test. Both the thermomechanical cycle and the bithermal technique can be used to study nonisothermal fatigue behavior. The difference between the two cycles is that in a conventional thermomechanical fatigue cycle the temperature is continuously varied concurrently with the applied mechanical strains, but in the bithermal fatigue cycle the specimen is held at zero load during the temperature excursions and all the loads are applied at the two extreme temperatures of the cycle. Experimentally, the bithermal fatigue test technique offers advantages such as ease in synchronizing the temperature and mechanical strain waveforms, in minimizing temperature gradients in the specimen gauge length, and in reducing and interpreting thermal fatigue such as the influence of alternate high and low temperatures on the cyclic stress-strain response characteristics, the effects of thermal state, and the possibility of introducing high- and low-temperature deformation mechanisms within the same cycle. The bithermal technique was used to study nonisothermal fatigue behavior of alloys such as single-crystal PWA 1480, single-crystal Rene N4, cast B1900+Hf, and wrought Haynes 188.

Verrilli, Michael J.↗
NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗
NASA NTRS1989

Notched fatigue of single crystal PWA 1480 at turbine attachment temperatures

The focus is on the lower temperature, uncoated and notched features of gas turbine blades. Constitutive and fatigue life prediction models applicable to these regions are being developed. Fatigue results are presented which were obtained thus far. Fatigue tests are being conducted on PWA 1480 single crystal material using smooth strain controlled specimens and three different notched specimens. Isothermal fatigue tests were conducted at 1200, 1400, and 1600 F. The bulk of the tests were conducted at 1200 F. The strain controlled tests were conducted at 0.4 percent per second strain rate and the notched tests were cycled at 1.0 cycle per second. A clear orientation dependence is observed in the smooth strain controlled fatigue results. The fatigue lifes of the thin, mild notched specimens agree fairly well with this smooth data when elastic stress range is used as a correlating parameter. Finite element analyses were used to calculate notch stresses. Fatigue testing will continue to further explore the trends observed thus far. Constitutive and life prediction models are being developed.

Meyer, T. G.↗
DOE OSTI2025

Hydrogen influences thermal activation parameters for dislocation glide during low cycle fatigue of 316L stainless steel

Measurements of activation areas are used to investigate the effect of hydrogen on the kinetics of dislocation glide during cyclic deformation in cold-worked 316L stainless steel. Non-charged and hydrogen-precharged (H-precharged) specimens were tested in low cycle fatigue (LCF) under plastic strain control. A series of plastic strain rate changes was performed periodically at the peak true plastic strain from the first cycle to half-life, and at various plastic strain values around stable hysteresis loops near half-life to determine the operational activation area, Δ a ∗. Both material conditions demonstrate a rapid increase in Δ a ∗ during the initial rapid softening followed by a region of approximately constant values coinciding with a reduced rate of softening. Near half-life, hydrogen reduces Δ a ∗ at a given true stress due to its effect on the activation distance and obstacle spacing. The magnitudes of Δ a ∗ reveal that bypassing solutes, cutting forest dislocations, and initiating cross slip are important mechanisms of thermally activated dislocation glide at all amplitudes, except hydrogen suppresses cross slip at the lowest plastic strain amplitudes. These results are supported by electron microscopy characterization of deformed microstructures. A Haasen plot analysis indicates that forest dislocations control the kinetics of deformation in both material conditions. It also reveals the presence of athermal obstacles in both non-charged and H-precharged conditions, likely dense dislocation tangles and cell walls. Additionally, the effect of hydrogen on microstructure evolution (by reducing the propensity for cross slip) leads to a dependence of athermal stress on plastic strain amplitude.

Activation area↗
DOE OSTI2021

Report on FY 2021 testing in support of integrating Alloy 800H and 2.25Cr-1Mo for EPP analysis

The use of simplified Elastic-Perfectly Plastic (EPP) design methods avoids the complexities and limitations of the elastic analysis approach in evaluating strain limits and creep-fatigue damage for Class A metallic coolant boundary components in ASME Boiler and Pressure Vessel Code, Section III, Division 5, Subsection HB, Subpart B. No stress classification and linearization are required in the EPP methods. Further, the strain limits and creep-fatigue damage evaluation procedures based on elastic analysis results were developed for the reactor operating conditions where uncoupled, rate-independent plasticity and stationary creep can be used to approximate the deformation in the component adequately. But at very high temperatures, the deformation is rate-dependent, and it can only be approximated adequately by unified viscoplastic model. Thus, for example, the elastic analysis approach cannot be used to evaluate strain limits and creep-fatigue damage for Alloy 617 above 650 °C. The EPP methods remove the temperature restriction. They can be used to evaluate strain limits and creep-fatigue damage for the full range of temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Summary of FY2024 Experimental Results to Support Development of New Inelastic Material Models and Validation of Section III, Division 5, Class A Design Rules

To address the data gap crucial for updating existing viscoplastic constitutive material models for the Class A materials in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME, 2023) for inelastic design analysis, Oak Ridge National Laboratory (ORNL) conducted experimental studies on Alloy 800H and Alloy 617 across a range of temperatures up to their maximum temperature limits in Section III, Division 5. The studies aim to characterize the materials' deformation behavior under both strain-controlled mechanical cyclic loading and thermal cycling conditions. This report summarizes ORNL's FY 2024 experimental findings on Alloy 800H and Alloy 617, focusing on pure fatigue tests, cyclic stress-strain curves, thermomechanical fatigue experiments, and verification of the high temperature cyclic damage summation design rules.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Procedures for characterizing an alloy and predicting cyclic life with the total strain version of Strainrange Partitioning

Procedures are presented for characterizing an alloy and predicting cyclic life for isothermal and thermomechanical fatigue conditions by using the total strain version of strainrange partitioning (TS-SRP). Numerical examples are given. Two independent alloy characteristics are deemed important: failure behavior, as reflected by the inelastic strainrange versus cyclic life relations; and flow behavior, as indicated by the cyclic stress-strain-time response (i.e., the constitutive behavior). Failure behavior is characterized by conducting creep-fatigue tests in the strain regime, wherein the testing times are reasonably short and the inelastic strains are large enough to be determined accurately. At large strainranges, stress-hold, strain-limited tests are preferred because a high rate of creep damage per cycle is inherent in this type of test. At small strainranges, strain-hold cycles are more appropriate. Flow behavior is characterized by conducting tests wherein the specimen is usually cycled far short of failure and the wave shape is appropriate for the duty cycle of interest. In characterizing an alloy pure fatigue, or PP, failure tests are conducted first. Then depending on the needs of the analyst a series of creep-fatigue tests are conducted. As many of the three generic SRP cycles are featured as are required to characterize the influence of creep on fatigue life (i.e., CP, PC, and CC cycles, respectively, for tensile creep only, compressive creep only, and both tensile and compressive creep). Any mean stress effects on life also must be determined and accounted for when determining the SRP inelastic strainrange versus life relations for cycles featuring creep. This is particularly true for small strainranges. The life relations thus are established for a theoretical zero mean stress condition.

Saltsman, James F.↗
NASA NTRS1991

Fatigue behavior and life prediction of a SiC/Ti-24Al-11Nb composite under isothermal conditions

Metal Matrix Composites (MMC) and Intermetallic Matrix Composites (IMC) were identified as potential material candidates for advanced aerospace applications. They are especially attractive for high temperature applications which require a low density material that maintains its structural integrity at elevated temperatures. High temperature fatigue resistance plays an important role in determining the structural integrity of the material. This study attempts to examine the relevance of test techniques, failure criterion, and life prediction as they pertain to an IMC material, specifically, unidirectional SiC fiber reinforced titanium aluminide. A series of strain and load controlled fatigue tests were conducted on unidirectional SiC/Ti-24Al-11Nb composite at 425 and 815 C. Several damage mechanism regimes were identified by using a strain-based representation of the data, Talreja's fatigue life diagram concept. Results of these tests were then used to address issues of test control modes, definition of failure, and testing techniques. Finally, a strain-based life prediction method was proposed for an IMC under tensile cyclic loadings at elevated temperatures.

Bartolotta, Paul A.↗
NASA NTRS1991

Stirling engine: Available tools for long-life assessment

A review is presented for the durability approaches applicable to long-time life assessment of Stirling engine hot-section components. The crucial elements are experimental techniques for generating long-time materials property data (both monotonic and cyclic flow and failure properties); analytic representations of slow strain rate material stress-strain response characteristics (monotonic and cyclic constitutive relations) at high temperatures and low stresses and strains; analytic creep-fatigue-environmental interaction life prediction methods applicable to long lifetimes at high temperatures and small stresses and strains; and experimental verification of life predictions. Long-lifetime design criteria for materials of interest are woefully lacking. Designing against failures due to creep, creep-rupture, fatigue, environmental attack, and creep-fatigue-environmental interaction will require considerable extrapolation. Viscoplastic constitutive models and time-temperature parameters will have to be calibrated for the hot-section materials of interest. Analysis combined with limited verification testing in a short-time regime will be required to build confidence in long-lifetime durability models.

Halford, Gary R.↗
NASA NTRS1991

Stirling engine - Available tools for long-life assessment

A review is presented for the durability approaches applicable to long-time life assessment of Stirling engine hot-section components. The crucial elements are experimental techniques for generating long-time materials property data (both monotonic and cyclic flow and failure properties); analytic representations of slow strain rate material stress-strain response characteristics (monotonic and cyclic constitutive relations) at high temperatures and low stresses and strains; analytic creep-fatigue-environmental interaction life prediction methods applicable to long lifetimes at high temperatures and small stresses and strains; and experimental verification of life predictions. Long-lifetime design criteria for materials of interest are woefully lacking. Designing against failures due to creep, creep-rupture, fatigue, environmental attack, and creep-failure-environmental interaction will require considerable extrapolation. Viscoplastic constitutive models and time-temperature parameters will have to be calibrated for the hot-section materials of interest. Analysis combined with limited verification testing in a short-time regime will be required to build confidence in long-lifetime durability models.

Halford, Gary R.↗
NASA NTRS1978

Strainrange partitioning behavior of the nickel-base superalloys, Rene 80 and IN-100

A study was made to assess the ability of the method of strainrange partitioning (SRP) to both correlate and predict high temperature, low cycle fatigue lives of nickel-base superalloys for gas turbine applications. Baseline data from strain-controlled, low cycle fatigue tests were expressed in terms of the PP, PC, CP, and CC partitioned inelastic strainrange versus life relationships for coated and uncoated Rene' 80 at 1000 C, Gatorized (creep-formed)IN 100 at 760 C, and cast IN 100 at 925 C. The SRP is shown to correlate the cyclic lives of the baseline tests to within factors of nearly two. The partitioned strainrange versus life relationships for uncoated Rene' 80 and cast IN 100 were also determined from the ductility normalized-strainrange partitioning equations. These were used to predict the cyclic lives of the baseline tests. Predicted and observed cyclic lives agreed to within factors of nearly three.

Halford, G. R.↗
NASA NTRS1994

Structurally compliant rocket engine combustion chamber: Experimental and analytical validation

A new, structurally compliant rocket engine combustion chamber design has been validated through analysis and experiment. Subscale, tubular channel chambers have been cyclically tested and analytically evaluated. Cyclic lives were determined to have a potential for 1000 percent increase over those of rectangular channel designs, the current state of the art. Greater structural compliance in the circumferential direction gave rise to lower thermal strains during hot firing, resulting in lower thermal strain ratcheting and longer predicted fatigue lives. Thermal, structural, and durability analyses of the combustion chamber design, involving cyclic temperatures, strains, and low-cycle fatigue lives, have corroborated the experimental observations.

Jankovsky, Robert S.↗
NASA NTRS1978

A strainrange partitioning analysis of low cycle fatigue of coated and uncoated Rene 80

A strainrange partitioning analysis was conducted on ultrahigh vacuum, strain-controlled, low-cycle fatigue behavior of uncoated and aluminide coated Rene' 80 nickel-base superalloy at 1000 C (1832 F) and 871 C (1600 F). The results indicated little effect of coating or temperature on the fatigue resistance. There was, however, a significant effect on fatigue life when creep was introduced into the strain cycles. The effect of this creep component was analyzed in terms of the method of strainrange partitioning.

Kortovich, C. S.↗
DOE OSTI2021

Role of deformation twinning in fatigue of CrCoNi medium-entropy alloy at room temperature

Here cylindrical specimens of CrCoNi alloy with electropolished surfaces were subjected to constant total strain amplitude low cycle fatigue. The alloy exhibited an initial period of cyclic hardening followed by cyclic softening until failure occurred. At the end of hardening stage at the peak of cyclic stress, well-developed persistent slip markings (PSMs) consisting of extrusions and intrusions were associated with thin deformation twins. A sophisticated experimental workflow was designed to extract information from the surface and the bulk of tested material. A combination of SEM, EBSD, ECCI, FIB and HR-STEM was used to study the internal structure and the surface profiles around the deformation twins, which were produced during the initial period of cyclic loading. Furthermore, localized cyclic plastic strain and stress concentrations near deformation twins led not only to early, well-developed PSMs, but also to the activation of TWIP and TRIP plasticity even at low macroscopic stress amplitudes.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Ductility normalized-strain-range partitioning life relations for creep-fatigue life predictions

Techniques utilizing strainrange partitioning may be used to estimate the effects of the environment on the high-temperature, low-cycle, creep-fatigue resistance of alloys. Three levels of ductility-normalized strainrange-partitioning life relations are discussed: (1) strainrange partitioning relations from ductility data, (2) strainrange partitioning relations scaled by ductility ratios, and (3) strainrange partitioning life relations with measured PP lines. The procedures have demonstrated good agreement with available creep-fatigue data.

Halford, G. R.↗