SEARCH · Search NASA

Results for “alloy optimization”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14

All sources NASA NTRS DOE OSTI

NASA NTRS1988

Growth of solid solution single crystals

Based on the thermophysical properties of Hg sub 1-x Cd sub x Te alloys, the reasons are discussed for the failure of conventional Bridgman-Stockbarger growth methods to produce high quality homogeneous crystals in the prescence of Earth's gravity. The deleterious effects are considered which arise from the dependence of the thermophysical properties on temperature and composition and from the large amount of heat carried by the fused silica ampules. An improved growth method, developed to optimize heat flow conditions, is described and experimental results are presented. The problems associated with growth in a gravitational environment are discussed. The anticipated advantages of growth in microgravity are given and the implications of the requirements for spaceflight experiments are summarized.

Lehoczky, S. L.↗

NASA NTRS1992

The LiAl/FeS2 battery power source for the future

Advanced high power density rechargeable batteries are currently under development. These batteries have the potential of greatly increasing the power and energy densities available for space applications. Depending on whether the system is optimized for high power or high energy, values up to 150 Wh/kg and 2100 W/kg (including hardware) are projected. This is due to the fact that the system uses a high conductivity molten salt electrolyte. The electrolyte also serves as a separator layer with unlimited freeze thaw capabilities. Life of 1000 cycles and ten calendar years is projected. The electrochemistry consists of a lithium aluminum alloy negative electrode, iron disulfide positive electrode, and magnesium oxide powder immobilized molten salt electrolyte. Processed powders are cold compacted into circular discs which are assembled into bipolar cell hardware with peripheral ceramic salts. The culmination of the work will be a high energy battery of 40 kWh and a high power battery of 28 kWh.

Briscoe, J. Douglass↗

NASA NTRS2020

OSA Spotlight Summary: Designing Miniature X-ray Optics for the SmallSat Lunar Science Mission Concept CubeX

The scientific demand for extended field X-Ray remote sensing for mapping of planetary bodies has produced the CubeSat X-ray Telescope (CubeX) lunar mission concept. Orbiting the Moon at 6,000 km for 1 year sometime during the mid-decade solar maximum, the primary objectives of CubeX are to map lunar surface elemental abundances and to assess feasibility of x-ray pulsar timing navigation. CubeX’s Miniature X-ray Optics (MiXO) design builds on heritage of existing X-ray imaging designs using new electroformed NiCo alloy replication (ENR) to create shells of 1 mm thickness. MiXO will provide 1 arcmin resolution X-Ray imaging for an extended instantaneous field of view, at various energy range sensitivities. Based on the classic Wolter-Type I design (using a paraboloid/hyperboloid grazing mirror pair), mirror parameters were expanded to allow both shell length and focal-plane offsets to vary independently. The design was optimized with a merit function that factored together four sub-merits: PSF sharpness (measured as half-power diameter), consistency across the field, minimized scattering, and maximized effective area. Monte Carlo analysis was used to predict final performance, including surface scatter effects. The demonstrated configurations include a compact 34 shell design with a diameter of 105 mm more efficient at higher energies, and a larger 130 mm/24 shell version with a larger overall effective area at lower energies. The compact design carries more expensive fabrication and assembly cost (with more shells) as well as a more challenging alignment (with denser packing). Both have overall resolution <1’ up to 26’ off-axis and <1.5’ up to 33’ off-axis, whereas a conventional design’s image quality degrades quickly beyond 15’ off-axis. This opens up new possibilities for future SmallSat missions that could use two different configurations for wide energy ranges or midsized instruments using multiple identical modules for larger collecting area.

x-ray↗

NASA NTRS2007

Notch Fatigue Strength of a PM Disk Superalloy

New powder metallurgy (PM) disk superalloys, such as ME3, LSHR, and Alloy 10, have been developed in recent years which enable rim temperatures in turbine disk applications to approach 1300 F. Before these alloys can be utilized at 1300 F their long term durability must be ensured. One of the key requirements for disk rims is notch fatigue strength. This issue is extremely important and is a direct result of the blade attachment geometry employed at the disk rim. Further, the imposition of a dwell at maximum load, associated with take off and landing, can also affect notch fatigue strength. For these reasons a study has been undertaken to assess the notch dwell fatigue strength of a modern PM disk alloy through spin pit evaluation of a prototypical disk. The first element of this program involves screening potential heat treatments with respect to notch fatigue strength at 1300 F utilizing a conventional notch fatigue specimen with a stress concentration factor (K(sub t)) of 2 and a 90 sec dwell at peak load. The results of this effort are reported in this paper including the downselect of an optimal heat treatment, from a notch fatigue standpoint.

Gayda, John↗

NASA NTRS2011

Active Flow Effectors for Noise and Separation Control

New flow effector technology for separation control and enhanced mixing is based upon shape memory alloy hybrid composite (SMAHC) technology. The technology allows for variable shape control of aircraft structures through actively deformable surfaces. The flow effectors are made by embedding shape memory alloy actuator material in a composite structure. When thermally actuated, the flow effector def1ects into or out of the flow in a prescribed manner to enhance mixing or induce separation for a variety of applications, including aeroacoustic noise reduction, drag reduction, and f1ight control. The active flow effectors were developed for noise reduction as an alternative to fixed-configuration effectors, such as static chevrons, that cannot be optimized for airframe installation effects or variable operating conditions and cannot be retracted for off-design or fail-safe conditions. Benefits include: Increased vehicle control, overall efficiency, and reduced noise throughout all f1ight regimes, Reduced flow noise, Reduced drag, Simplicity of design and fabrication, Simplicity of control through direct current stimulation, autonomous re sponse to environmental heating, fast re sponse, and a high degree of geometric stability. The concept involves embedding prestrained SMA actuators on one side of the chevron neutral axis in order to generate a thermal moment and def1ect the structure out of plane when heated. The force developed in the host structure during def1ection and the aerodynamic load is used for returning the structure to the retracted position. The chevron design is highly scalable and versatile, and easily affords active and/or autonomous (environmental) control. The technology offers wide-ranging market applications, including aerospace, automotive, and any application that requires flow separation or noise control.

Turner, Travis L.↗

NASA NTRS2023

Additive Manufacturing Process Development DOE for NASA HR-1 using Laser Blown Powder Directed Energy Deposition

NASA HR-1 is a Fe-Ni-Cr alloy that is used for high pressure hydrogen applications such as rocket engines, energy, and oil and gas. This investigation was focused on conducting a design of experiment program aimed at mapping the parameter process window for NASA HR-1 using the laser blown powder directed energy deposition (LP-DED) process. A two phased design of experiments (DOE), the first phase of the experiment was focused on optimizing single bead tracks while the second phase of the experiment was focused on optimizing bead overlap hatching in a multi pass bead build up. During the first phase of the deposition parameters, namely laser power, travel speed, and powder feed rate were varied. A down selection from the single bead parameter set was made and hatching experiments were conducted that focused on the overlap distance. In this paper the approach for conducting the DOE and results are discussed. The results focused on measurement of bead geometry, the as-built microstructural evolution, and porosity within the samples. The team at MSFC saw a variety of results across the process map created during the first phase of experimentation and were able to down select a parameter that created an optimal bead shape with a minimal amount of build porosity. It was determined that laser power and robot travel speed were the most sensitive parameters. The results from this investigation will inform future laser powder directed energy deposition parameter developments.

Parker Shake↗

NASA NTRSDate not supplied

Design and Analysis of Shape Memory Spring Tires for Martian and Lunar Rover Vehicles

Shape memory alloys (SMAs) have played an important role in various innovative engineering and medical applications, such as aerospace actuators, vibration damping devices, and coronary stents. In applications, shape memory alloys are commonly utilized in two fundamentally different ways: (i) making use of the superelasticity/ pseudoelasticity (SE/PE) phenomena, as in applications in biomedical engineering, and (ii) taking advantages of the shape memory effect (SME), as is used for actuators. Their ability to act in such vastly different capacities is mainly due to their unique capability to recover large amounts of deformation produced by either applied stresses or temperature changes. One recent emerging application in use of SMAs has been in the area of non-pneumatic tire designs for Martian or Lunar roving vehicles. These vehicles require tires that are capable of traversing rugged terrain while withstanding extreme temperatures and atmospheric conditions. Inspired by the flexible wire mesh tires used on three Lunar Roving Vehicle (LRV) missions to the Moon on Apollo 15, 16, and 17, a new compliant tire technology was developed by the NASA Glenn Research Center (GRC) and Goodyear Tire & Rubber, known as the Spring Tire. The Spring Tire consists of several hundred coiled springs woven into a flexible mesh and formed into the shape of a tire. Like the LRV wire mesh tires, the original Spring Tires were made from spring steel and were prone to permanent deformation when undergoing high localized loads. Later, a new iteration of this technology was invented, known as the ‘Superelastic Tire’. This new technology incorporated the use of superelastic SMA springs, which could effectively undergo approximately 30 times more reversible deformation than the steel spring. It also provided even greater durability and allowed for more flexibility in design, such as the use of other structural forms to reduce mass or increase load carrying capacity. Because of the unique nature of both the SMA material and the complex interactions between the springs, designing Spring Tires for a specific application requires extensive effort. Historically, design decisions have relied on full-scale empirical testing; however, this is very expensive and time consuming, especially when multiple iterations are needed. Therefore, developing a large-scale, robust, and predictive numerical model entailing complex spring interactions and the shape memory material behavior within a tire construct is the first essential step towards a successful design program. The current work focuses on implementation of the user-defined Shape Memory Alloy (SMA) model, otherwise known as SMA-GVIPs, in the Finite Element analysis (FEA) program ABAQUS for large-scale simulations of the GRC-developed Spring Tires made of SMA. The novelty of this work lies in the thorough, detail-oriented, and computationally efficient finite element analysis of full-scale SMA tires. A well-thought material characterization plan followed by model validation and a systemic sensitivity study on SMA tires has never been reported in the previous literature. The main objective of this study is to help the team improve and optimize the structural design of the SMA tires through in-depth numerical analysis and sensitivity studies. Various design variables (wire diameter, coil diameter, pitch, bead angle, and number of springs) were varied to study their influence on the global load-displacement response of the tire construct. A detailed investigation of the three-dimensional stress states was also carried out to enhance our understanding of the local changes as the tire goes through global deformation. It was concluded that a robust numerical model with a good predictive capability, together with a thoughtfully crafted sensitivity study can result in improved design iterations required to reach a desired tire performance while, significantly reducing manufacturing, labor and testing expenses. A summary of the Finite Element (FE) model construction will be presented together with a description of the user-defined SMA model, characterization process, experimental results, model validation, and numerical sensitivity study results.

shape memory alloys↗

NASA NTRS2005

Low Conductive Thermal Barrier Coatings Produced by Ion Beam Assisted EB-PVD with Controlled Porosity, Microstructure Refinement and Alloying Additions for High Temperature Applications

Various advanced Hafnia-based thermal barrier coatings (TBC) were applied on nickel-based superalloy coupons by electron beam physical vapor deposition. In addition, microstructural modifications to the coating material were made in an effort to reduce the thermal conductivity of the coating materials. Various processing parameters and coating system modifications were made in order to deposit the alloyed TBC with the desired microstructure and thus coating performance, some of which include applying coatings at substrate temperatures of 1150 C on both PtAl and CoNiCrAlY bond coated samples, as well as using 8YSZ as a bond layer. In addition, various characterization techniques including thermal cyclic tests, scanning electron microscopy, x-ray diffraction, thermal conductivity, and reflectivity measurements were performed. Although the coating microstructure was never fully optimized due to funding being cut short, significant reductions in thermal conductivity were accomplished through both chemistry changes (composition) and microstructural modifications.

Wolfe, Douglas E.↗

NASA NTRS2019

Characterization of 10-ft. Diameter Aluminum Alloy 2219 Integrally Stiffened Cylinders

The integrally stiffened cylinder (ISC) process, pioneered by NASA Langley Research Center, offers significant savings for launch vehicle structures. The ISC process is a near net shape, advanced manufacturing method for fabrication of single-piece, thin-walled barrels with internal longitudinal stiffeners, eliminating the need for longitudinal welding and machining. A cost-benefit analysis of the ISC process estimated a 50 % reduction in manufacturing costs and a 10% weight savings over the current multi-piece, machined and welded construction approach for stiffened barrels. In 2017, commercial-scale manufacturing trials were pursued, leading to a successful manufacturing demonstration of 10-ft. diameter ISC barrels fabricated from Al alloy 2219. Some cracking was observed in the stiffeners during fabrication. Optical metallography was performed to evaluate the as-formed microstructures to identify potential causes of cracking, along with mechanical testing to evaluate formability. Results revealed that cracking in the stiffeners was attributed to three likely causes: 1) large Al-Cu stringer particles, 2) stick-slip friction between the mandrel and ISC due to non-optimized lubrication, and 3) differences in material flow rate between the wall and stiffener locations. Testing to gauge formability revealed a significant decrease in ductility in the longitudinal directional for the as-formed condition, attributed to reduced ductility due to the large Al-Cu stringer particles. These results provide guidance toward materials and processing modifications for future ISC forming trials.

Tayon, Wesley A.↗

NASA NTRS2020

Additive Manufacture of Refractory Alloy C103 for Propulsion Applications

C103 is niobium alloy used in high temperature operating environments. Traditional manufacture methods suffer from feedstock constraints, difficult to machine, high buy-to-fly ratios, and high costs resulting in a limited number of suppliers. Additive manufacture (AM) offers advantages in production of complex parts, improved properties, reproducibility, with significant material cost and schedule savings. The objectives of this project was to investigate the feasibility to AM C103, develop powder feedstock, optimize process parameters, establish design criteria, investigate post-process heat treatments, and determine material properties. AM C103 proved feasible, increased design flexibility, improved mechanical properties compared to wrought, and resulted in an order of magnitude cost reduction.

Omar R Mireles↗

NASA NTRSDate not supplied

Additive Manufacture of Refractory Alloy C103 for Propulsion Applications

Omar Roberto Mireles↗

NASA NTRS1989

Multiple doping of silicon-germanium alloys for thermoelectric applications

It is shown that heavy doping of n-type Si/Ge alloys with phosphorus and arsenic (V-V doping interaction) by diffusion leads to a significant enhancement of their carrier concentration and possible improvement of the thermoelectric figure of merit. High carrier concentrations were achieved by arsenic doping alone, but for a same doping level higher carrier mobilities and lower resistivities are obtained through phosphorus doping. By combining the two dopants with the proper diffusion treatments, it was possible to optimize the different properties, obtaining high carrier concentration, good carrier mobility and low electrical resistivity. Similar experiments, using the III-V doping interaction, were conducted on boron-doped p-type samples and showed the possibility of overcompensating the samples by diffusing arsenic, in order to get n-type behavior.

Fleurial, Jean-Pierre↗

NASA NTRS1972

Small-scale explosive seam welding

A unique small scale explosive seam welding technique is reported that has successfully joined a variety of aluminum alloys and alloy combinations in thicknesses to 0.125 inch, as well as titanium in thicknesses to 0.056 inch. The explosively welded joints are less than one-half inch in width and apparently have no long length limitation. The ribbon explosive developed in this study contains very small quantities of explosive encased in a flexible thin lead sheath. The evaluation and demonstration of this welding technique was accomplished in three phases: evaluation and optimization of ten major explosive welding variables, the development of four weld joints, and an applicational analysis which included photomicrographs, pressure integrity tests, vacuum effects, and fabrication of some potentially useful structures in aluminum and titanium.

Bement, L. J.↗

NASA NTRS2001

Friction Stir Welding at MSFC: Kinematics

In 1991 The Welding Institute of the United Kingdom patented the Friction Stir Welding (FSW) process. In FSW a rotating pin-tool is inserted into a weld seam and literally stirs the faying surfaces together as it moves up the seam. By April 2000 the American Welding Society International Welding and Fabricating Exposition featured several exhibits of commercial FSW processes and the 81st Annual Convention devoted a technical session to the process. The FSW process is of interest to Marshall Space Flight Center (MSFC) as a means of avoiding hot-cracking problems presented by the 2195 aluminum-lithium alloy, which is the primary constituent of the Lightweight Space Shuttle External Tank. The process has been under development at MSFC for External Tank applications since the early 1990's. Early development of the FSW process proceeded by cut-and-try empirical methods. A substantial and complex body of data resulted. A theoretical model was wanted to deal with the complexity and reduce the data to concepts serviceable for process diagnostics, optimization, parameter selection, etc. A first step in understanding the FSW process is to determine the kinematics, i.e., the flow field in the metal in the vicinity of the pin-tool. Given the kinematics, the dynamics, i.e., the forces, can be targeted. Given a completed model of the FSW process, attempts at rational design of tools and selection of process parameters can be made.

Nunes, A. C., Jr.↗

NASA NTRS2003

Microsample Characterization of Coatings for Grcop-84 for High Heat Flux Applications

A multidisciplinary Johns Hopkins University-NASA Glenn team is undertaking a collaborative research program to elucidate and model the thermal stability and mechanical integrity of candidate coatings for GRCop-84. GRCop-84 is a high conductivity, high strength copper alloy that was recently developed at NASA Glenn for use in high temperature, high heat flux applications. With potential applications in rocket motor combustion chamber liners, nozzle ramps and other actively cooled structures, this new material offers great potential for decreasing weight and increasing reliability of third generation reusable launch vehicles. Current emphasis has turned toward the development of environmentally resistant and thermal barrier coatings for this alloy. Metallic coatings such as NiCrAlY and Cu-8-30%Cr have shown promise in: prohibiting blanching, reducing dog-house failures, increasing operating temperatures and decreasing cooling requirements. The focus of this research program is to develop a fundamental understanding of the substrate-coating interactions that occur during thermal cycling (inter-diffusion, viscoplasticity, morphological evolution, crack formation, etc.) and to derive a science-based protocol for future coating selection, optimization and reliability assurance. The microsample tensile testing approach adopted for this study allows us to characterize small-scale and highly scale-specific coatings and properties in a way not possible by conventional means. In addition to providing much needed design data, the integration of microsample testing with detailed microstructural observations provides a mechanistic foundation for coating optimization and life prediction modeling.

Hemker, Kevin↗

NASA NTRS2002

FSW Implementation on the Space Shuttle's External Tank

The Friction Stir Welding process developed by The Welding Institute (TWI) has found application throughout the transportation industry. This technique has proven to be a viable joining process for aluminum alloys, producing virtually defect free welds with improved mechanical properties as compared to conventional fusion welding. Lockheed Martin Space Systems - Michoud Operations has been developing this technology for application on aluminum 2219 and 2195 cryogenic tankage since 1995. This effort will come to fruition with implementation on the longitudinal welds of the External Fuel Tank (ET) of the Shuttle. To this end, sub-and full-scale demonstration programs coupled with process development and optimization have been complete. Full size ET tool has been designed, fabricated and are being installed at the Michoud Assembly Facility. Upon completion of the tooling certification and materials allowables testing, production will commence. This implementation will result in increased reliability and safety of flight for the Shuttle.

Hartley, Paula J.↗

NASA NTRS1993

Development of dispersion-strengthened XD (trademark) Cu alloys for high heat-flux applications

In a previous effort sponsored by NASA LeRC, the XD(trademark) process was used to produce ZrB2 particulate reinforcements in Cu and the resulting extruded material was microstructurally characterized and evaluated in tension over a range of temperatures. A problem that was encountered in that study was microstructural inhomogeneity resulting from the frequent presence of 'ZrB2 agglomerates' that were several microns in size. The presence of these agglomerates was attributed to improper mixing of powders in the green compact used in the XD process for elemental boron powder segregation. In this program, several milling parameters were examined in an effort to optimize this processing step; two levels of ZrB2 reinforcements were considered (7 vol. percent and 15 vol. percent). Microstructures of the reacted powder mass were examined to verify the absence of these agglomerates. Larger bathes of powder were then mixed, reacted, machined to size, canned, and extruded. The microstructure and tensile properties of these extrusions were examined, and the measured properties were correlated with the observed microstructure. Large unreacted or partially reacted Zr particles were present. These particles affected the mechanical properties deleteriously, and their presence is attributed to insufficient heat of reaction during XD synthesis. Alternate processing routes are recommended.

Kumar, K. Sharvan↗

NASA NTRS2002

Compression Buckling Behavior of Large-Scale Friction Stir Welded and Riveted 2090-T83 Al-Li Alloy Skin-Stiffener Panels

To evaluate the potential of friction stir welding (FSW) as a replacement for traditional rivet fastening for launch vehicle dry bay construction, a large-scale friction stir welded 2090-T83 aluminum-lithium (Al-Li) alloy skin-stiffener panel was designed and fabricated by Lockheed-Martin Space Systems Company - Michoud Operations (LMSS) as part of NASA Space Act Agreement (SAA) 446. The friction stir welded panel and a conventional riveted panel were tested to failure in compression at the NASA Langley Research Center (LaRC). The present paper describes the compression test results, stress analysis, and associated failure behavior of these panels. The test results provide useful data to support future optimization of FSW processes and structural design configurations for launch vehicle dry bay structures.

Hoffman, Eric K.↗