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At least 271 records · Page 15

Applications of Thin Film Thermocouples for Surface Temperature Measurement

Thin film thermocouples provide a minimally intrusive means of measuring surface temperature in hostile, high temperature environments. Unlike wire thermocouples, thin films do not necessitate any machining of the surface, therefore leaving intact its structural integrity. Thin films are many orders of magnitude thinner than wire, resulting in less disruption to the gas flow and thermal patterns that exist in the operating environment. Thin film thermocouples have been developed for surface temperature measurement on a variety of engine materials. The sensors are fabricated in the NASA Lewis Research Center's Thin Film Sensor Lab, which is a class 1000 clean room. The thermocouples are platinum-13 percent rhodium versus platinum and are fabricated by the sputtering process. Thin film-to-leadwire connections are made using the parallel-gap welding process. Thermocouples have been developed for use on superalloys, ceramics and ceramic composites, and intermetallics. Some applications of thin film thermocouples are: temperature measurement of space shuttle main engine turbine blade materials, temperature measurement in gas turbine engine testing of advanced materials, and temperature and heat flux measurements in a diesel engine. Fabrication of thin film thermocouples is described. Sensor durability, drift rate, and maximum temperature capabilities are addressed.

Martin, Lisa C.↗

Analysis of the Erosion of Cubic Centered and Face Centered Metallic Materials [Analyse de L'erosion de Matereaux Metalliques de Structures Cubiques Centree et Face Centree]

A generalized law of erosion, in nondimensional form, is proposed. The aforementioned explicitly gives an account of the nature and the microstructure of the material impacted, the angle of impact of the particles, and their hardness. The erosion behavior of various steels, pig iron, and cast iron is examined as well as the behavior of new ordered intermetallic materials, Fe-25% Al-(Zr, Cr, B). The concern of such alloys in an erosion-corrosion environment is shown. --- Une loi généralisée d'usure par érosion, sous forme non dimensionnelle, est proposée. Celle-ci rend compte explicitement de la nature et de la microstructure du matériau impacté, de l'angle d'impact des particules, de leur acuité at de leur durete. Le comportement à l'érosion de divers aciers et fontes est examiné ainsi que la tenue de nouveaux matériaux intermétalliques ordonnés Fe-25% Al - (Zr, Cr, B). L'interet de tels alliages dans des environnements agressifs du type érosion-corrosion est montré. Mots clés: usure, érosion, modèle, matériaux métalliques, intermétalliques Fe-Al.

A Magnée↗

Nial and Nial-Based Composites Directionally Solidified by a Containerless Zone Process

A containerless electromagnetically levitated zone (CELZ) process has been used to directionally solidify NiAl and NiAl-based composites. The CELZ processing results in single crystal NiAl (HP-NiAl) having higher purity than commercially pure NiAl grown by a modified Bridgman process (CP-NiAl). The mechanical properties, specifically fracture toughness and creep strength, of the HP-NiAl are superior to binary CP-NiAl and are used as a base-line for comparison with the composite materials subsequently studied. Two-phase composite materials (NiAl-based eutectic alloys) show improvement in room temperature fracture toughness and 1200 to 1400 K creep strength over that of binary HP-NiAl. Metallic phase reinforcements produce the greatest improvement in fracture toughness, while intermetallic reinforcement produces the largest improvement in high temperature strength. Three-phase eutectic alloys and composite materials were identified and directionally solidified with the intent to combine the improvements observed in the two-phase alloys into one alloy. The room temperature fracture toughness and high temperature strength (in air) serve as the basis for comparison between all of the alloys. Finally, the composite materials are discussed in terms of dominant fracture mechanism observed by fractography.

Joslin, Steven M.↗

Evaluation of Rhenium Joining Methods

Coupons of rhenium-to-Cl03 flat plate joints, formed by explosive and diffusion bonding, were evaluated in a series of shear tests. Shear testing was conducted on as-received, thermally-cycled (100 cycles, from 21 to 1100 C), and thermally-aged (3 and 6 hrs at 1100 C) joint coupons. Shear tests were also conducted on joint coupons with rhenium and/or Cl03 electron beam welded tabs to simulate the joint's incorporation into a structure. Ultimate shear strength was used as a figure of merit to assess the effects of the thermal treatment and the electron beam welding of tabs on the joint coupons. All of the coupons survived thermal testing intact and without any visible degradation. Two different lots of as-received, explosively-bonded joint coupons had ultimate shear strengths of 281 and 310 MPa and 162 and 223 MPa, respectively. As-received, diffusion-bonded coupons had ultimate shear strengths of 199 and 348 MPa. For the most part, the thermally-treated and rhenium weld tab coupons had shear strengths slightly reduced or within the range of the as-received values. Coupons with Cl03 weld tabs experienced a significant reduction in shear strength. The degradation of strength appeared to be the result of a poor heat sink provided during the electron beam welding. The Cl03 base material could not dissipate heat as effectively as rhenium, leading to the formation of a brittle rhenium-niobium intermetallic.

Reed, Brian D.↗

Reliability analysis of single crystal NiAl turbine blades

As part of a co-operative agreement with General Electric Aircraft Engines (GEAE), NASA LeRC is modifying and validating the Ceramic Analysis and Reliability Evaluation of Structures algorithm for use in design of components made of high strength NiAl based intermetallic materials. NiAl single crystal alloys are being actively investigated by GEAE as a replacement for Ni-based single crystal superalloys for use in high pressure turbine blades and vanes. The driving force for this research lies in the numerous property advantages offered by NiAl alloys over their superalloy counterparts. These include a reduction of density by as much as a third without significantly sacrificing strength, higher melting point, greater thermal conductivity, better oxidation resistance, and a better response to thermal barrier coatings. The current drawback to high strength NiAl single crystals is their limited ductility. Consequently, significant efforts including the work agreement with GEAE are underway to develop testing and design methodologies for these materials. The approach to validation and component analysis involves the following steps: determination of the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; measurement of the failure strength envelope of the material; coding of statistically based reliability models; verification of the code and model; and modeling of turbine blades and vanes for rig testing.

Salem, Jonathan↗

Development and Processing of Nickel Aluminide-Carbide Alloys

With the upper temperature limit of the Ni-based superalloys attained, a new class of materials is required. Intermetallics appear as likely candidates because of their attractive physical properties. With a relatively low density, high thermal conductivity, excellent oxidation resistance, high melting point, and simple crystal structure, nickel aluminide (NiAl) appears to be a potential candidate. However, NiAl is limited in structural applications due to its low room temperature fracture toughness and poor elevated temperature strength. One approach to improving these properties has been through the application of eutectic composites. Researchers have shown that containerless directional solidification of NiAl-based eutectic alloys can provide improvement in both the creep strength and fracture toughness. Although these systems have shown improvements in the mechanical properties, the presence of refractory metals increases the density significantly in some alloys. Lower density systems, such as the carbides, nitrides, and borides, may provide NiAl-based eutectic structure. With little or no information available on these systems, experimental investigation is required. The objective of this research was to locate and develop NiAl-carbide eutectic alloys. Exploratory arc-melts were performed in NiAl-refractory metal-C systems. Refractory metal systems investigated included Co, Cr, Fe, Hf, Mo, Nb, Ta, Ti, W, and Zr. Systems containing carbides with excellent stability (i.e.,HfC, NbC, TaC, TiC, and ZrC) produced large blocky cubic carbides in an NiAl matrix. The carbides appeared to have formed in the liquid state and were randomly distributed throughout the polycrystalline NiAl. The Co, Cr, Fe, Mo, and W systems contained NiAl dendrites with a two-phase interdendritic microconstituent present. Of these systems, the NiAl-Mo-C system had the most promising microstructure for in-situ composites. Three processing techniques were used to evaluate the NiAl-Mo-C system: arc-melting, slow cooling, and containerless directional solidification. Arc-melting provided a wide range of compositions in an economical and simple fashion. The slow cooled ingots provided larger ingots and slower cooling rates than arc-melting. Directional solidification was used to produce in-situ composites consisting of NiAl reinforced with molybdenum carbides.

Newport, Timothy Scott↗

High temperature braided rope seals for static sealing applications

Achieving efficiency and performance goals of advanced aircraft and industrial systems are leading designers to implement high temperature materials such as ceramics and intermetallics. Generally these advanced materials are applied selectively in the highest temperature sections of the engine system including the combustor and high pressure turbine, amongst others. Thermal strains that result in attaching the low expansion-rate components to high expansion rate superalloy structures can cause significant life reduction in the components. Seals are being designed to both seal and to serve as compliant mounts allowing for relative thermal growths between high temperature but brittle primary structures and the surrounding support structures. Designers require high temperature, low-leakage, compliant seals to mitigate thermal stresses and control parasitic and cooling airflow between structures. NASA is developing high temperature braided rope seals in a variety of configurations to help solve these problems. This paper will describe the types of seals being developed, describe unique test techniques used to assess seal performance, and present leakage flow data under representative pressure, temperature and scrubbing conditions. Feasibility of the braided rope seals for both an industrial tube seal and a turbine vane seal application is also demonstrated.

Adams, Michael L.↗

Fatigue Crack Growth and Crack Bridging in SCS-6/Ti-24-11

Interfacial damage induced by relative fiber/matrix sliding was found to occur in the bridged zone of unidirectional SCS-6/Ti-24Al-11Nb intermetallic matrix composite specimens subjected to fatigue crack growth conditions. The degree of interfacial damage was not uniform along the bridged crack wake. Higher damage zones were observed near the machined notch in comparison to the crack tip. The interfacial friction shear strength tau(sub f) measured in the crack wake using pushout testing revealed lower values than the as-received interface. Interfacial wear also reduced the strength of the bridging fibers. The reduction in fiber strength is thought to be a function of the magnitude of relative fiber/matrix displacements ind the degree of interfacial damage. Furthermore, two different fiber bridging models were used to predict the influence of bridging on the fatigue crack driving force. The shear lag model required a variable tau(sub f) in the crack wake (reflecting the degradation of the interface) before its predictions agreed with trends exhibited by the experimental data. The fiber pressure model did an excellent job in predicting both the FCG data and the DeltaCOD in the bridged zone even though it does not require a knowledge of tau(sub f).

Ghosn, Louis J.↗

Processing and Mechanical Properties of Directionally Solidified NiAl/NiAlTa Alloys

Promising creep strengths were found for a directionally solidified NiAl-NiAlTa alloy when compared to other NiAl based intermetallics. The directionally solidified alloy had an off-eutectic composition that resulted in microstructures consisting of NiAl dendrites surrounded by aligned eutectic regions. The room temperature toughness of the two phase alloy was similar to that of polycrystalline NiAl even with the presence of the brittle Laves phase NiAlTa. Alloying additions that may improve the room temperature toughness by producing multiphase alloys are discussed.

Johnson, D. R.↗

[?]Nonlinear Issues in the Aerothermochemistry of Gases and Materials and the Associated Physics and Dynamics of Interfaces

Our research and technology are focused on nonlinear issues in the aerothermochemistry of gases and materials and the associated physics and dynamics of interfaces. Our program is now organized to aggressively support the NASA Aeronautics Enterprise so as to: (a) develop a new generation of environmentally compatible, economic subsonic aircraft; (b) develop the technology base for an economically viable and environmentally compatible high-speed civil transport; (c) develop the technology options for new capabilities in high-performance aircraft; (d) develop hypersonic technologies for air-breathing flight; and (e) develop advanced concepts, understanding of physical phenomena, and theoretical, experimental, and computational tools for advanced aerospace systems. The implications from our research for aeronautical and aerospace technology have been both broad and deep. For example, using advanced computational techniques, we have determined exact solutions for the Schrodinger equation in electron-molecule scattering allowing us to evaluate atmospheric models important to reentry physics. We have also found a new class of exact solutions for the Navier Stokes equations. In experimental fluid dynamics, we have found explicit evidence of turbulence modification of droplet sizes in shock tube flow with condensation. We have developed a new diagnostic tool for the direct estimation of flow velocities at MHz sampling rates in quasi-one dimensional turbulent flow. This procedure suggests an unexpected confirmation of the possibility of 'natural' closure in Reynolds stresses with deep implications for the development of turbulent models. A transient increase is observed in both the spectral energy decay rate and the degree of chaotic complexity at the interface of a shock wave and a turbulent ionized gas. Even though the gas is apparently brought to rest by the shock wave, no evidence is found either of the expected relaminarization. A unique diamond-shaped nozzle has been designed for a detailed investigation of the effect of significant streamwise vorticity on the acoustic and IR characteristics of supersonic jets. Our results provide convincing evidence of the significant effect of vorticity on the far-field noise for the diamond jet as compared to the conventional round jets. We have found that the countercurrent shear layer mixes much more efficiently than conventional coflowing shear layers. We also developed the fluid thrust vectoring procedures which use counter flow to vector a jet. Our materials research has shown that the steep stress gradients at the fiber-matrix interface could be the primary cause of interface cracks after the processing of metallic and intermetallic matrix composites. New techniques have been evolved for: the microcharacterization of materials including microplastic strain and, point by point, the misorientation and plasticity for matrix composites; thermally induced stress measurements and load relaxation; the growth and characterization of metallic matrix composite interfaces; and for the growth of ferrite materials by pulsed laser deposition. The FAMU commitment to the HBCU Research Center also continues to be broad and deep.

Johnson, Joseph A., III↗

MoSi2-Base Composite for Engine Applications

The intermetallic compound MoSi2 has long been known as a high temperature material that has excellent oxidation resistance and electrical/thermal conductivity. Also its low cost, high melting point (2023 C), relatively low density (6.2 g/cm versus 8 g/cm for current engine materials), and ease of machining make it an attractive structural material. However, the use of MoSi2 has been hindered because of the brittle nature of the material at low temperatures, inadequate creep resistance at high temperatures, accelerated oxidation (also known as 'pest' oxidation) at temperatures between approximately 400 and 500 C, and a coefficient of thermal expansion (CTE) that is relatively high in comparison to potential reinforcing fibers such as SiC. This CTE mismatch between the fiber and the matrix resulted in severe matrix cracking during thermal cycling.

Hebsur, Mohan G.↗

The Influence of C and Si on the Flow Behavior of NiAl Single Crystals

Alloys based on the intermetallic compound NiAl are considered potential replacements for Ni and Co-based superalloys in high temperature structural applications due to their excellent oxidation resistance, low densities, high thermal conductivities, and increased melting points. Unfortunately, NiAl exhibits low tensile ductility at room temperature and low strengths at elevated temperatures which have combined to hinder its development. Recent efforts, have revealed that NiAl in the presence of sufficient solute levels, is subject to the phenomenon of strain aging which manifests itself as: sharp yield points, abnormally low strain rate sensitivities (SRS), plateaus or peaks in yield stress and work hardening rate as a function of temperature, flow stress transients upon an upward change in strain rate, reduced tensile elongations at elevated temperatures, and serrated stress-strain curves. Though recent efforts via either alloying or the removal of interstitial impurities, have resulted in consistent room-temperature tensile elongations exceeding 5% and the elimination of serrated flow, the effects of particular substitutional and interstitial elements and the mechanisms by which they might enhance or hinder the mechanical properties remain unknown. Consequently, the purpose of the present paper is to provide a preliminary assessment of the influence of common substitutional and interstitial impurities on the deformation behavior of NiAl. To accomplish this goal a series of NiAl single crystal alloys containing various interstitial solutes were prepared and their mechanical properties were evaluated between 77 and 1100 K. Because Si is a common impurity in conventional purity single crystals grown by the Bridgman method, Si concentrations were also varied in order to determine the influence of this element.

Weaver, M. L.↗

Effects of Compression, Staging, and Braid Angle on Braided Rope Seal Performance

Future turbine engines and industrial systems will be operating at increased temperatures to achieve more demanding efficiency and performance goals. In the highest temperature sections of the engine new material systems such as ceramics and intermetallics are being considered to withstand the harsh thermal environment. Components constructed of these low expansion-rate materials experience thermal strains and a resulting reduction of life when rigidly attached to high expansion-rate, superalloy support structures. Seals are being designed to both seal and to serve as compliant mounts allowing for relative thermal growths between high temperature but brittle primary structures and the surrounding support structures. Previous seal research yielded several braided rope seal designs which demonstrated the ability to both seal and serve as a compliant mount. The hybrid seal was constructed of an all-ceramic (alumina-silica) core overbraided with a superalloy wire sheath (cobalt based superalloy). The all ceramic seal was constructed of an all-ceramic (alumina-silica) core overbraided with multiple ceramic (alumina-silica) sheath layers. Program goals for braided rope seals are to improve flow resistance and/or seal resilience. To that end, the current report studies the test results of: baseline and modified hybrid seals; two stage hybrid and two stage all-ceramic seal configurations; and single stage hybrid and single stage all-ceramic seal configurations for a range of seal crush conditions. Hybrid seal modifications include increasing the sheath braid angle and core coverage. For the same percent seal cross-sectional crush, results show that increasing the hybrid seal braid angle increased seal stiffness and seal unit load, resulting in flows approximately one third of the baseline hybrid seal flows. For both hybrid and all-ceramic seals, two stage seal configurations significantly outperformed single stage configurations. Two stage seal flows were at least 30% less than the single stage seal flows for the same seal crush. Furthermore, test results of single stage seals indicate that for both all-ceramic and hybrid seals, a specific seal crush condition exists at which minimum flows are achieved (i.e. increasing seal crush beyond a certain point does not result in better flow performance). Flow results are presented for a range of pressures and temperatures from ambient to 1300 F, before and after scrubbing. Compression tests results show that for both all-ceramic and hybrid seals, seal preload and stiffness increase with seal crush, but residual seal interference remains constant.

Steinetz, Bruce M.↗

Determination of Residual Stress in Composite Materials Using Ultrasonic Waves

The performance of high temperature composites can be significantly affected by the presence of residual stresses. These stresses arise during cooling processes from fabrication to room temperature due to mismatch of thermal expansion coefficients between matrix and fiber materials. This effect is especially pronounced in metal matrix and intermetallic composites. It can lead to plastic deformations, matrix cracking and fiber/matrix interface debonding. In this work the feasibility of ultrasonic techniques for residual stress assessment in composites is addressed. A novel technique for absolute stress determination in orthotropic materials from angular dependencies of ultrasonic velocities is described. The technique is applicable for determination of both applied and residual stresses and does not require calibration measurements on a reference sample. The important advantage of this method is that stress is determined simultaneously with stress-dependent elastic constants and is thus decoupled from the material texture. It is demonstrated that when the principal plane stress directions coincide with acoustical axes, the angular velocity data in the plane perpendicular to the stress plane may be used to determine both stress components. When the stress is off the acoustical axes, the shear and the difference of the normal stress components may be determined from the angular dependence of group velocities in the plane of stresses. Synthetic sets of experimental data corresponding to materials with different anisotropy and stress levels are used to check the applicability of the technique. The method is also verified experimentally. A high precision ultrasonic wave transmission technique is developed to measure angular dependence of ultrasonic velocities. Examples of stress determination from experimental velocity data are given. A method is presented for determination of velocities of ultrasonic waves propagating through the composite material with residual stresses. It is based on the generalized self-consistent multiple scattering model. Calculation results for longitudinal and shear ultrasonic wave velocities propagating perpendicular to the fibers direction in SCS-6/Ti composite with and without residual stresses are presented. They show that velocity changes due to presence of stresses are of order 1%.

Rokhlin, S. I.↗

Directional Solidification and Mechanical Properties of NiAl-NiAlTa Alloys

Directional solidification of eutectic alloys is a promising technique for producing in-situ composite materials exhibiting a balance of properties. Consequently, the microstructure, creep strength and fracture toughness of directionally solidified NiAl-NiAlTa alloys were investigated. Directional solidification was performed by containerless processing techniques to minimize alloy contamination. The eutectic composition was found to be NiAl-15.5 at% Ta and well-aligned microstructures were produced at this composition. A near-eutectic alloy of NiAl-14.5Ta was also investigated. Directional solidification of the near-eutectic composition resulted in microstructures consisting of NiAl dendrites surrounded by aligned eutectic regions. The off-eutectic alloy exhibited promising compressive creep strengths compared to other NiAl-based intermetallics, while preliminary testing indicated that the eutectic alloy was competitive with Ni-base single crystal superalloys. The room temperature toughness of these two-phase alloys was similar to that of polycrystalline NiAl even with the presence of the brittle Laves phase NiAlTa.

Johnson, D. R.↗

Development and Characterization of SiC)/ MoSi2-Si3N4(p) Hybrid Composites

Intermetallic compound MoSi2 has long been known as a high temperature material that has excellent oxidation resistance and electrical/thermal conductivity. Also its low cost, high melting point (2023 C), relatively low density (6.2 g/cu cm versus 9 g/cu cm for current engine materials), and ease of machining, make it an attractive structural material. However, the use of MoSi2 has been hindered due to its poor toughness at low temperatures, poor creep resistance at high temperatures, and accelerated oxidation (also known as 'pest' oxidation) at temperatures between approximately 450 and 550 C. Continuous fiber reinforcing is very effective means of improving both toughness and strength. Unfortunately, MoSi2 has a relatively high coefficient of thermal expansion (CTE) compared to potential reinforcing fibers such as SiC. The large CTE mismatch between the fiber and the matrix resulted in severe matrix cracking during thermal cycling. Addition of about 30 to 50 vol % of Si3N4 particulate to MoSi2 improved resistance to low temperature accelerated oxidation by forming a Si2ON2 protective scale and thereby eliminating catastrophic 'pest failure'. The Si3N4 addition also improved the high temperature creep strength by nearly five orders of magnitude, doubled the room temperature toughness and significantly lowered the CTE of the MoSi2 and eliminated matrix cracking in SCS-6 reinforced composites even after thermal cycling. The SCS-6 fiber reinforcement improved the room temperature fracture toughness by seven times and impact resistance by five times. The composite exhibited excellent strength and toughness improvement up to 1400 C. More recently, tape casting was adopted as the preferred processing of MoSi2-base composites for improved fiber spacing, ability to use small diameter fibers, and for lower cost. Good strength and toughness values were also obtained with fine diameter Hi-Nicalon tow fibers. This hybrid composite remains competitive with ceramic matrix composites as a replacement for Ni-base superalloys in aircraft engine applications.

Hebsur, Mohan G.↗

Undercooling, Rapid Solidification, and Relations to Processing in Low Earth Orbit (A Review of the Works of Bingbo Wei)

This is a survey of the published works of Prof. Bingbo Wei of the Department of Applied Physics at Northwestern Polytechnical University, Xian P.R. China. Transformations among solid - liquid - and vapor are fundamental to the foundations of life and culture on Earth. The development and understanding of materials has lead the evolution and advancement of the human race since antiquity. Materials and fluids research is continuing today, with us standing on the shoulders of those that have gone before us. Technological and scientific breakthroughs continue due to studies of greater and greater complexity, that include for example, research done at high pressures, in high magnetic fields, at temperatures near absolute zero, and in the low gravity environment of low Earth orbit. Of particular technological importance is the liquid to solid transformation of metals and alloys. Solidification processing is generally the most important factor in the final properties of objects made of metal; and undercooling is the fundamental driving force for all solidification. The interest and resources dedicated to the study of solidification and undercooling are great and World wide. For many years B. Wei and his coworkers have been studying undercooling and rapid solidification and have amassed a significant body of published research in this important field, contributing to the leading edge of the state-of-the-art. It is the goal of this memorandum to provide a review of the research of B. Wei et al.; publications in Chinese are included in the reference list but are not discussed. The bulk of Wei's work has been in the area of undercooling and rapid solidification [1-11, 13-16, 24-36] with papers dating back to 1989, the same year he earned his Ph.D. Below, discussions of Wei's undercooling and rapid solidification research have been grouped together mostly on the basis of alloy type, such as eutectic, intermetallic, or monotectic.

deGroh, Henry C., III↗

Enhanced CARES Software Enables Improved Ceramic Life Prediction

The NASA Lewis Research Center has developed award-winning software that enables American industry to establish the reliability and life of brittle material (e.g., ceramic, intermetallic, graphite) structures in a wide variety of 21st century applications. The CARES (Ceramics Analysis and Reliability Evaluation of Structures) series of software is successfully used by numerous engineers in industrial, academic, and government organizations as an essential element of the structural design and material selection processes. The latest version of this software, CARES/Life, provides a general- purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. CARES/Life was recently enhanced by adding new modules designed to improve functionality and user-friendliness. In addition, a beta version of the newly-developed CARES/Creep program (for determining the creep life of monolithic ceramic components) has just been released to selected organizations.

Janosik, Lesley A.↗