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Tensile, fatigue, and creep rupture properties of extruded nickel-based aluminum, titanium carbide, and beryllium oxide alloys and aluminum-based silicon, copper, and iron alloys
Comparison of creep-rupture properties of electron beam-melted polycrystalline and powder- metallurgy rhenium sheets at 2200 to 4200 F and 4 to 40 ksi
Heat treatment of carbide and boride strengthened chromium alloys to improve tensile and creep rupture strength
Thermomechanical processing of nickel alloy in relation to yield and creep rupture strength
Creep and creep rupture deformation and tensile tests of nickel alloys
Creep rupture behavior of electron beam melted polycrystalline sheet and powdered rhenium
A computer program was developed to analyze the transient afterheat temperature and pressure response of a mobile gas-cooled reactor power plant following impact. The program considers (in addition to the standard modes of heat transfer) fission product decay and transport, metal-water reactions, core and shield melting and displacement, and pressure and containment vessel stress response. Analyses were performed for eight cases (both deformed and undeformed models) to verify operability of the program options. The results indicated that for a 350 psi (241 n/sq cm) initial internal pressure, the containment vessel can survive over 100,000 seconds following impact before creep rupture occurs. Recommendations were developed as to directions for redesign to extend containment vessel life.
Using NASA IIb as a base composition, the effects of five key elements (carbon, tungsten, tantalum, aluminum, and hafnium) on resultant properties were investigated in an effort to optimize the composition and derive new wrought high temperature alloys with improved strength characteristics. A total of nineteen compositions were melted, extruded, and rolled to bar stock using thermomechanical processing. Both full and partial solution heat treatments were developed for the compositions. Tensile properties from room temperature to 1800 deg F, stress and creep rupture properties to 1800 deg F, and thermal stability characteristics were evaluated. NASA IIb-7 exhibited the best response to the partial solution heat treatment for optimum properties up to 1200 deg F. The alloy contained 0.13C, 9.0 Cr, 9.0 Co, 2.0 Mo, 7.5 W, 10.0 Ta, 3.5 Al, 0.75 Ti, 0.02 B, 0.10 Zr, 0.50 V, 1.0 Hf, and balance nickel.
A CO2 laser heated, floating zone fiber growth process was developed. The resulting Al2O3 fibers exhibited the high room temperature strengths for large diameter fibers as well as high specific creep rupture strengths observed at 1093 C and 1316 C (2000 F and 2400 F). Single crystal fibers of TiC and Y2O3 were also grown. An optical system was developed to focus four CO2 laser beams onto the surface of a feed rod permitting the formation of highly controllable molten zones. The optical system permitted energy densities and angle of incidence of the beams to be adjusted over wide ranges. This optical system was incorporated into a controlled atmosphere, fiber growth furnace. The two principal advantages of a CO2 laser heat source are that ambient atmospheres may be freely selected to optimize fiber properties and the laser has no inherent temperature limit, so extremely high melting point materials can be melted. Both advantages were demonstrated.
Time-dependent notch sensitivity of Inconel 718 sheet occurred at 900 to 1200 F when notched specimens were loaded below the yield strength, and tests on smooth specimens showed that small amounts of creep consumed large fractions of creep-rupture life. The severity of the notch sensitivity decreased with decreasing solution treatment temperature and increasing time and/or temperature of the aging treatment. Elimination of the notch sensitivity was correlated with a change in the dislocation mechanism from shearing to by-passing precipitate particles.
A method termed 'enhanced diffusion welding' has been developed to produce solid-state welds in TD-NiCr (Ni-20Cr-2ThO2) alloy sheet with weld strengths of 100% of the parent metal strength. Diffusion welded joints were made in specially processed TD-NiCr that equaled the tensile-shear and creep-rupture shear strengths of the parent material at 1090 deg C. The following observations have been made: specially processed TD-NiCr is preferred over commercial TD-NiCr for diffusion welding; the weld line can be eliminated when joining specially processed TD-NiCr by 600-grit sanding and electropolishing the faying surfaces prior to welding; and, a two-step weld cycle is preferred for diffusion welding of this alloy.
An improved diffusion welding technique has been developed for TD-NiCr sheet. In the most preferred form, the improved technique consists of diffusion welding 320-grit sanded plus chemically polished surfaces of unrecrystallized TD-NiCr at 760 C under 140 MN/m2 pressure for 1hr followed by postheating at 1180 C for 2hr. Compared to previous work, this improved technique has the advantages of shorter welding time, lower welding temperature, lower welding pressure, and a simpler and more reproducible surface preparation procedure. Weldments were made that had parent-metal creep-rupture shear strength at 1100 C.
Various tests were conducted to determine the mechanical properties of 12 alloys that are commonly used or proposed for use in pressurized gaseous hydrogen or hydrogen containing environments. Properties determined in the hydrogen environments were compared to properties determined in a pure helium environment at the same conditions to establish environmental degradation. The specific mechanical properties tested include: high-cycle fatigue, low-cycle fatigue, fracture mechanics, creep-rupture, and tensile.
Final stretch criterion of failure is applied to the problem of quasi-static extension of a crack embedded in an elastic-plastic or viscoelastic-plastic matrix. The slow growth under subcritical conditions in a rate-sensitive Tresca solid is shown to be a superposition of creep rupture and McClintock's ductile growth. This type of growth occurs at subcritical magnitude of the imposed K-factor and can be accounted for only through a recognition of inelastic properties of solids. In the subcritical range there is no unique value for K sub c independent of geometrical configuration and flaw size. Not only the produced states of stress and strain are dependent on the loading path, but also the material resistance to fracture turns out to be a function of the history of loading that precedes catastrophic failure. A nonlinear integro-differential equation of motion is derived for a crack progressing through a viscoelastic medium with some limited ability to plastic flow. Examples of numerical integration are given incorporating both monotonic and cyclic loading programs.
A program was conducted to develop nickel-base superalloy disk material using prealloyed powder metallurgy techniques. The program included fabrication of test specimens and subscale turbine disks from four different prealloyed powders (NASA-TRW-VIA, AF2-1DA, Mar-M-432 and MERL 80). Based on evaluation of these specimens and disks, two alloys (AF2-1DA and Mar-M-432) were selected for scale-up evaluation. Using fabricating experience gained in the subscale turbine disk effort, test specimens and full scale turbine disks were formed from the selected alloys. These specimens and disks were then subjected to a rigorous test program to evaluate their physical properties and determine their suitability for use in advanced performance turbine engines. A major objective of the program was to develop processes which would yield alloy properties that would be repeatable in producing jet engine disks from the same powder metallurgy alloys. The feasibility of manufacturing full scale gas turbine engine disks by thermomechanical processing of pre-alloyed metal powders was demonstrated. AF2-1DA was shown to possess tensile and creep-rupture properties in excess of those of Astroloy, one of the highest temperature capability disk alloys now in production. It was determined that metallographic evaluation after post-HIP elevated temperature exposure should be used to verify the effectiveness of consolidation of hot isostatically pressed billets.
Solid specimens of the alloy Inconel 903 (iron based alloy) were exposed to four gaseous environments and high temperatures. Air, pure helium, pure hydrogen, and hydrogen and water vapor combined were the gaseous environments employed, and the temperature was 1400 F. Various mechanical property tests (low cycle fatigue, creep-rupture, tensile properties) were performed on the alloy. Results indicate that the hydrogen and water vapor environment cause a sharp reduction in the mechanical properties of the alloy. Photographs of the test equipment used and the microstructure of the tested alloy are included.
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.
During a test program to investigate low-cycle thermal fatigue, 13 rocket combustion chambers were fabricated and cyclically test fired to failure. Six oxygen-free, high-conductivity (OFHC) copper and seven Amzirc chambers were tested. The failures in the OFHC copper chambers were not typical fatigue failures but are described as creep rupture enhanced by ratcheting. The coolant channels bulged toward the chamber centerline, resulting in progressive thinning of the wall during each cycle. The failures in the Amzirc alloy chambers were caused by low-cycle thermal fatigue. The zirconium in this alloy was not evenly distributed in the chamber materials. The life that was achieved was nominally the same as would have been predicted from OFHC copper isothermal test data.