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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Effect of Processing Route on Strain Controlled Low Cycle Fatigue Behavior of Polycrystalline NiAl

The present investigation examines the effects of manufacturing process on the total axial strain controlled low cycle fatigue behavior of polycrystalline NiAl at 1000 K, a temperature above the monotonic Brittle-to-Ductile Transition Temperature (BDTT). The nickel aluminide samples were produced by three different processing routes: hot isostatic pressing of pre- alloyed powders, extrusion of prealloyed powders, and extrusion of vacuum induction melted ingots. The LCF behavior of the cast plus extruded material was also determined at room temperature (below the BD77) for comparison to the high temperature data. The cyclic stress response, cyclic stress-strain behavior, and strain-life relationships were influenced by the alloy preparation technique and the testing temperature. Detailed characterization of the LCF tested samples was conducted by optical and electron microscopy to determine the variations in fracture and deformation modes and to determine any microstructural changes that occurred during LCF testing. The dependence of LCF properties on processing route was rationalized on the basis of starting microstructure, brittle-to-ductile transition temperature, deformation induced changes in the basic microstructure, deformation substructure, and synergistic interaction between the damage modes.

Rao, K. Bhanu Sankara↗
NASA NTRS1998

Feasibility Study for Casting of High Temperature Refractory Superalloy Composites

Abstract This study investigated the feasibility of using conventional casting technique to fabricate refractory wires reinforced superalloy composites. These composites were being developed for advanced rocket engine turbine blades and other high temperature applications operating up to 2000 F. Several types of refractory metal wires such as W- Th, W-Re, Mo-Hf-C and W-HF-C reinforced waspaloy were experimentally cast and heat treated at 2000 F up to 48 hrs. Scanning electron microscope analysis was conducted in regions adjacent to the wire-matrix interface to determine the reaction zone and chemical compatibility resulting from material interdiffusion. It was concluded that fabrication using conventional casting may be feasible because the wire-matrix reaction zone thickness was comparable to similar composites produced by arc-sprayed monotape with hot isostatic pressing technique, Moreover, it was also found that the chemical compatibility could be improved significantly through a slight modification of the superalloy matrix compositions.

Lee, Jonathan A.↗
NASA NTRS2000

The Effect of Boron on the Low Cycle Fatigue Behavior of Disk Alloy KM4

The durability of powder metallurgy nickel base superalloys employed as compressor and turbine disks is often limited by low cycle fatigue (LCF) crack initiation and crack growth from highly stressed surface locations (corners, holes, etc.). Crack growth induced by dwells at high stresses during aerospace engine operation can be particularly severe. Supersolvus solution heat treatments can be used to produce coarse grain sizes approaching ASTM 6 for improved resistance to dwell fatigue crack growth. However, the coarse grain sizes reduce yield strength, which can lower LCF initiation life. These high temperature heat treatments also can encourage pores to form. In the advanced General Electric disk superalloy KM4, such pores can initiate fatigue cracks that limit LCF initiation life. Hot isostatic pressing (HIP) during the supersolvus solution heat treatment has been shown to improve LCF initiation life in KM4, as the HIP pressure minimizes formation of the pores. Reduction of boron levels in KM4 has also been shown to increase LCF initiation life after a conventional supersolvus heat treatment, again possibly due to effects on the formation tendencies of these pores. However, the effects of reduced boron levels on microstructure, pore characteristics, and LCF failure modes in KM4 still need to be fully quantified. The objective of this study was to determine the effect of boron level on the microstructure, porosity, LCF behavior, and failure modes of supersolvus heat treated KM4.

Gabb, Timothy↗
NASA NTRS2003

The Cryogenic Properties of Several Aluminum-Beryllium Alloys and a Beryllium Oxide Material

Performance related mechanical properties for two aluminum-beryllium (Al-Be) alloys and one beryllium-oxide (BeO) material were developed at cryogenic temperatures. Basic mechanical properties (Le., ultimate tensile strength, yield strength, percent elongation, and elastic modulus were obtained for the aluminum-beryllium alloy, AlBeMetl62 at cryogenic [-195.5"C (-320 F) and -252.8"C (-423"F)I temperatures. Basic mechanical properties for the Be0 material were obtained at cyrogenic [- 252.8"C (-423"F)] temperatures. Fracture properties were obtained for the investment cast alloy Beralcast 363 at cryogenic [-252.8"C (-423"F)] temperatures. The AlBeMetl62 material was extruded, the Be0 material was hot isostatic pressing (HIP) consolidated, and the Beralcast 363 material was investment cast.

Gamwell, Wayne R.↗
NASA NTRS2003

Cryogenic Properties of Aluminum Beryllium and Beryllium Materials

Ultimate tensile strength, yield strength, and elongation were obtained for the aluminum-beryllium alloy, AlBeMetl62 (38%Al-62%Be), at cryogenic (-195.5 C (-320 F) and (-252.8 C) (-423 F)) temperatures, and for an optical grade beryllium, O-30H (99%Be), at -252.8 C. AlBeMetl62 material was purchased to the requirements of SAE-AMS7912, "Aluminum-Beryllium Alloy, Extrusions." O-30H material was purchased to the requirements of Brush Wellman Inc. specification O-30H Optical Grade Beryllium. The ultimate tensile and yield strengths for extruded AlBeMetl62 material increased with decreasing temperature, and the percent elongation decreased with decreasing temperature. Design properties for the ultimate tensile strength, yield strength, and percent elongation for extruded AlBeMetl62 were generated. It was not possible to distinguish a difference in the room and cryogenic ultimate strength for the hot isostatically pressed (HIP'ed) O-30H material. The O30H elongation decreased with decreasing temperature.

Gamwell, Wayne R.↗
NASA NTRS2003

Cryogenic Properties of Aluminum-Beryllium and Beryllium Materials

Ultimate tensile strength, yield strength, and elongation were obtained for the aluminum- beryllium alloy, AlBeMetl62 (38%Al-62%Be), at cryogenic (-195.5 C (-32O F) and (- 252.8 C) (-423 F)) temperatures, and for an optical grade beryllium, O-30H (99%Be), at -252.8 C. AlBeMet162 material was purchased to the requirements of SAE- AMs7912, "Aluminum-Beryllium Alloy, Extrusions". O-30H material was purchased to the requirements of Brush Wellman Inc. specification O-30H Optical Grade Beryllium. The ultimate tensile and yield strengths for extruded AlBeMet162 material increased with decreasing temperature, and the percent elongation decreased with decreasing temperature. Design properties for the ultimate tensile strength, yield strength, and percent elongation for extruded AlBeMetl62 were generated. It was not possible to distinguish a difference in the room and cryogenic ultimate strength for the hot isostatically pressed (HIP'ed) O-30H material. The O-30H elongation decreased with decreasing temperature.

Gamwell, Wayne R.↗
NASA NTRS2005

Net-Shape HIP Powder Metallurgy Components for Rocket Engines

True net shape consolidation of powder metal (PM) by hot isostatic pressing (HIP) provides opportunities for many cost, performance and life benefits over conventional fabrication processes for large rocket engine structures. Various forms of selectively net-shape PM have been around for thirty years or so. However, it is only recently that major applications have been pursued for rocket engine hardware fabricated in the United States. The method employs sacrificial metallic tooling (HIP capsule and shaped inserts), which is removed from the part after HIP consolidation of the powder, by selective acid dissolution. Full exploitation of net-shape PM requires innovative approaches in both component design and materials and processing details. The benefits include: uniform and homogeneous microstructure with no porosity, irrespective of component shape and size; elimination of welds and the associated quality and life limitations; removal of traditional producibility constraints on design freedom, such as forgeability and machinability, and scale-up to very large, monolithic parts, limited only by the size of existing HIP furnaces. Net-shape PM HIP also enables fabrication of complex configurations providing additional, unique functionalities. The progress made in these areas will be described. Then critical aspects of the technology that still require significant further development and maturation will be discussed from the perspective of an engine systems builder and end-user of the technology.

Bampton, Cliff↗
NASA NTRS2003

High-Temperature Oxidation-Resistant and Low Coefficient of Thermal Expansion NiAl-Base Bond Coat Developed for a Turbine Blade Application

Many critical gas turbine engine components are currently made from Ni-base superalloys that are coated with a thermal barrier coating (TBC). The TBC consists of a ZrO2-based top coat and a bond coat that is used to enhance the bonding between the superalloy substrate and the top coat. MCrAlY alloys (CoCrAlY and NiCrAlY) are currently used as bond coats and are chosen for their very good oxidation resistance. TBC life is frequently limited by the oxidation resistance of the bond coat, along with a thermal expansion mismatch between the metallic bond coat and the ceramic top coat. The aim of this investigation at the NASA Glenn Research Center was to develop a new longer life, higher temperature bond coat by improving both the oxidation resistance and the thermal expansion characteristics of the bond coat. Nickel aluminide (NiAl) has excellent high-temperature oxidation resistance and can sustain a protective Al2O3 scale to longer times and higher temperatures in comparison to MCrAlY alloys. Cryomilling of NiAl results in aluminum nitride (AlN) formation that reduces the coefficient of thermal expansion (CTE) of the alloy and enhances creep strength. Thus, additions of cryomilled NiAl-AlN to CoCrAlY were examined as a potential bond coat. In this work, the composite alloy was investigated as a stand-alone substrate to demonstrate its feasibility prior to actual use as a coating. About 85 percent of prealloyed NiAl and 15 percent of standard commercial CoCrAlY alloys were mixed and cryomilled in an attritor with stainless steel balls used as grinding media. The milling was carried out in the presence of liquid nitrogen. The milled powder was consolidated by hot extrusion or by hot isostatic pressing. From the consolidated material, oxidation coupons, four-point bend, CTE, and tensile specimens were machined. The CTE measurements were made between room temperature and 1000 C in an argon atmosphere. It is shown that the CTE of the NiAl-AlN-CoCrAlY composite bond coat is lower than that of the commercially used coating alloy 16-6. To examine the potential of NiAl-AlN-CoCrAlY as a bond coat, we subjected two samples to cyclic furnace testing. The furnace cycle consisted of 45 min at 1163 C (2125 F ) followed by 15 min of cooling out of the furnace. The current NASA baseline TBC is a NiCrAlY bond coat below the 7YSZ top coat. The average TBC life for this baseline coating on Ren N5 is 188 plus or minus 19 cycles. NiAl-AlN-CoCrAlY specimens coated with the same 7YSZ top coat were still intact even after 1000 cycles. Therefore, the NiAl-AlN-CoCrAlY as a bulk substrate material, exhibits more than 5 times the life of the current state-of-the-art material. The next step is to evaluate this material as a coating on the same superalloy substrate.

Source record↗
NASA NTRS2003

Particulate Titanium Matrix Composites Tested-Show Promise for Space Propulsion Applications

New manufacturing technologies can now produce uniformly distributed particle strengthened titanium matrix composites (TMCs) at lower cost than many types of continuous-fiber composites. The innovative process results in near-final-shape components having a material stiffness up to 26-percent greater than that of components made with conventional titanium materials. This benefit is achieved with no significant increase in the weight of the component. The improved mechanical performance and low-cost manufacturing capability motivated a review of particulate-reinforced metal composite technology as a way to lower the cost and weight of space-access propulsion systems. Focusing on the elevated-temperature properties of titanium alloy Ti-6Al-4V as the matrix material, researchers at the NASA Glenn Research Center conducted experiments to verify the improved performance of the alloy containing 10 wt% of ceramic titanium carbide (TiC) particles. The appropriate blend of metal and ceramic powder underwent a series of cold and hot isostatic pressing procedures to yield bar stock. A set of round dogbone specimens was manufactured from a small sample of the bars. The TMC material proved to have good machinability at this particle concentration as there was no difficulty in producing high-quality specimens.

Thesken, John C.↗
NASA NTRS2004

Particulate Titanium Matrix Composites Tested--Show Promise for Space Propulsion Applications

Uniformly distributed particle-strengthened titanium matrix composites (TMCs) can be manufactured at lower cost than many types of continuous-fiber composites. The innovative manufacturing technology combines cold and hot isostatic pressing procedures to produce near-final-shape components. Material stiffness is increased up to 26-percent greater than that of components made with conventional titanium materials at no significant increase in the weight. The improved mechanical performance and low-cost manufacturing capability motivated an independent review to assess the improved properties of ceramic titanium carbide (TiC) particulate-reinforced titanium at elevated temperature. Researchers at the NASA Glenn Research Center creatively designed and executed deformation and durability tests to reveal operating regimes where these materials could lower the cost and weight of space propulsion systems. The program compares the elevated-temperature performance of titanium alloy Ti-6Al-4V matrix material to an alloy containing 10 wt% of TiC particles. Initial experiments showed that at these relatively low particle concentrations the material stiffness of the TMC was improved 20 percent over that of the plain Ti-6Al-4V alloy when tested at 427 C. The proportional limit and ultimate strength of the composite in tension are 21- and 14-percent greater than those of the plain alloy. Compression tests showed that the proportional limit is about 30 percent greater for TMC than for the plain alloy. The enhanced deformation resistance of the TMC was also evident in a series of tensile and compressive stress relaxation tests that were made. Specimens were subjected to tensile or compressive strain amplitudes of 0.75 percent for 24 hr followed by a return to zero strain imposed for 24 hr. The stress relaxation data were normalized with respect to the maximum stress for each case and plotted as a function of time in the following graph. Tensile stresses relaxed 19 percent for the TMC and 25 percent for the plain Ti-6Al-4V alloy. Compressive stresses relaxed 25 percent for the TMC and 39 percent for the plain Ti-6Al-4V alloy. The superior deformation resistance of the TMC extends to a creep rate that is 28-percent slower for the TMC when it is loaded to stress levels that are 26-percent higher than for the plain Ti-6Al-4V alloy.

Lerch, Bradley A.↗
NASA NTRS2006

Life Test Approach for Refractory Metal/Sodium Heat Pipes

Heat pipe life tests described in the literature have seldom been conducted on a systematic basis. Typically one or more heat pipes are built and tested for an extended period at a single temperature with simple condenser loading. This paper describes an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. Approximately 10 years of operational life might be compressed into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Two specific test series have been identified and include: investigation of long term corrosion rates based on the guidelines contained in ASTM G-68-80 (using 7 heat pipes); and investigation of corrosion trends in a cross correlation sequence at various temperatures and mass fluences based on a central composite test design (using 9 heat pipes). The heat pipes selected for demonstration purposes are fabricated from a Mo-44.5%Re alloy with a length of 0.3 meters and a diameter of 1.59 cm(to conserve material) with a condenser to evaporator length ratio of approximately 3. The wick is a crescent annular design formed from 400-mesh Mo-Re alloy material hot isostatically pressed to produce a final wick core of 20 microns or less.

Martin, James J.↗
NASA NTRS2006

Methodology for Life Testing of Refractory Metal/Sodium Heat Pipes

The focus of this work was to establish an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. To accomplish this goal acceleration is required to compress 10 years of operational life into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Specific test series have been identi3ed, based on American Society for Testing and Materials (ASTM) specifications, to investigate long term corrosion rates. The refractory metal selected for demonstration purposes is a Molybdenum-44.5%Rhenium alloy formed by powder metallurgy. The heat pipe makes use of an annular crescent wick design formed by hot isostatic pressing of Molybdenum-Rhenium wire mesh. The heat pipes are filled using vacuum distillation and purity sampling is considered. Testing of these units is round-the-clock with 6-month destructive and non-destructive inspection intervals to identify the onset and level of corrosion. Non-contact techniques are employed for providing power to the evaporator (radio frequency induction heating at I to 5 kW per unit) and calorimetry at the condenser (static gas gap coupled water cooled calorimeter). The planned operating temperature range would extend from 1123 to 1323 K. Accomplishments prior to project cancellation included successful demonstration of the heat pipe wick fabrication technique, establishment of all engineering designs, baselined operational test requirements and procurement/assembly of supporting test hardware systems.

Martin, James J.↗
NASA NTRS2007

Recent Progress in the Development of Neodymium Doped Ceramic Yttria

Solid-state lasers play a significant role in providing the technology necessary for active remote sensing of the atmosphere. Neodymium doped yttria (Nd:Y2O3) is considered to be an attractive material due to its possible lasing wavelengths of aprrox.914 nm and approx.946 nm for ozone profiling. These wavelengths when frequency tripled can generate UV light at approx.305 nm and approx.315 nm, which is particularly useful for ozone sensing using differential absorption lidar technique. For practical realization of space based UV transmitter technology, ceramic Nd:Y2O3 material is considered to possess great potential. A plasma melting and quenching method has been developed to produce Nd3+ doped powders for consolidation into Nd:Y2O3 ceramic laser materials. This far-from-equilibrium processing methodology allows higher levels of rare earth doping than can be achieved by equilibrium methods. The method comprises of two main steps: (a) plasma melting and quenching to generate dense, and homogeneous doped metastable powders, (b) pressure assisted consolidation of these powders by hot isostatic pressing to make dense nanocomposite ceramics. Using this process, several 1" x 1" ceramic cylinders have been produced. The infrared transmission of undoped Y2O3 ceramics was as high as approx.75% without anti-reflection coating. In the case of Nd:Y2O3 ceramics infrared transmission values of approx.50% were achieved. Furthermore, Nd:Y2O3 samples with dopant concentrations of up to approx.2 at. % were prepared without significant emission quenching.

Prasad, Narasimha S.↗
NASA NTRS2012

Tensile Properties of GRCop-84

This is a chapter in the final report on GRCop-84 for the Reusable Launch Vehicle (RLV) Second Generation/Project Constellation Program. It contains information on the tensile properties of GRCop-84. GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) was produced by extrusion and Hot Isostatic Pressing (HIPing). Some of the extrusions were rolled to plate and sheet while other extrusions were drawn into tubing. The material was further subjected to various heat treatments corresponding to annealing, anticipated typical brazing conditions, an end-of-life condition and various elevated temperature exposures to attempt to improve creep resistance. As anticipated, cold work increased strength while decreasing ductility. Annealing at 600 C (1112 F) and higher temperatures was effective. An exposure for 100 h at 500 C (932 F) resulted in an increase in strength rather than the anticipated decrease. High temperature simulated-braze cycles and thermal exposures lowered the strength of GRCop-84, but the deceases were small compared to precipitation strengthened copper alloys. It was observed that the excess Cr could form large precipitates that lower the reduction in area though it appears a minimum amount is required. Overall, GRCop-84 exhibits good stability of its tensile properties, which makes it an excellent candidate for rocket engine liners and many other high temperature applications.

Ellis, David L.↗
NASA NTRS2012

Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors

High-precision mirrors for space applications are traditionally manufactured from one piece of material, such as lightweight glass sandwich or beryllium. The purpose of this project was to develop and test the feasibility of a manufacturing process capable of producing mirrors out of welded segments of AlBeMet(Registered Trademark) (AM162H). AlBeMet(Registered Trademark) is a HIP'd (hot isostatic pressed) material containing approximately 62% beryllium and 38% aluminum. As a result, AlBeMet shares many of the benefits of both of those materials for use in high performance mirrors, while minimizing many of their weaknesses.

Vudler, Vladimir↗
NASA NTRS2012

Charpy Impact Energy and Microindentation Hardness of 60-NITINOL

60-NITINOL (60 wt.% Ni 40 wt.% Ti) is being studied as a material for advanced aerospace components. The Charpy impact energy and microindentation hardness has been studied for this material, fabricated by vacuum induction skull melting (casting) and by hot isostatic pressing. Test specimens were prepared in various hardened and annealed heat treatment conditions. The average impact energy ranged from 0.33 to 0.49J for the hardened specimens while the annealed specimens had impact energies ranging from 0.89 to 1.18J. The average hardness values of the hardened specimens ranged from 590 to 676 HV while that of the annealed specimens ranged from 298 to 366 HV, suggesting an inverse relationship between impact energy and hardness. These results are expected to provide guidance in the selection of heat treatment processes for the design of mechanical components.

Stanford, Malcolm K.↗
NASA NTRS2013

Closeout Report for the Refractory Metal Accelerated Heat Pipe Life Test Activity

With the selection of a gas-cooled reactor, this heat pipe accelerated life test activity was closed out and its resources redirected. The scope of this project was to establish the long-term aging effects on Mo-44.5%Re sodium heat pipes when subjected to space reactor temperature and mass fluences. To date, investigators have demonstrated heat pipe life tests of alkali metal systems up to .50,000 hours. Unfortunately, resources have not been available to examine the effect of temperature, mass fluence, or impurity level on corrosion or to conduct post-test forensic examination of heat pipes. The key objective of this effort was to establish a cost/time effective method to systematically test alkali metal heat pipes with both practical and theoretical benefits. During execution of the project, a heat pipe design was established, a majority of the laboratory test equipment systems specified, and operating and test procedures developed. Procurements for the heat pipe units and all major test components were underway at the time the stop work order was issued. An extremely important outcome was the successful fabrication of an annular wick from Mo-5%Re screen (the single, most difficult component to manufacture) using a hot isostatic pressing technique. This Technical Publication (TP) includes specifics regarding the heat pipe calorimeter water-cooling system, vendor design for the radio frequency heating system, possible alternative calorimeter designs, and progress on the vanadium equilibration technique. The methods provided in this TP and preceding project documentation would serve as a good starting point to rapidly implement an accelerated life test. Relevant test data can become available within months, not years, and destructive examination of the first life test heat pipe might begin within 6 months of test initiation. Final conclusions could be drawn in less than a quarter of the mission duration for a long-lived, fission-powered, deep space probe.

Martin, J.↗
NASA NTRS2015

Thermal Pyrolytic Graphite Enhanced Components

A thermally conductive composite material, a thermal transfer device made of the material, and a method for making the material are disclosed. Apertures or depressions are formed in aluminum or aluminum alloy. Plugs are formed of thermal pyrolytic graphite. An amount of silicon sufficient for liquid interface diffusion bonding is applied, for example by vapor deposition or use of aluminum silicon alloy foil. The plugs are inserted in the apertures or depressions. Bonding energy is applied, for example by applying pressure and heat using a hot isostatic press. The thermal pyrolytic graphite, aluminum or aluminum alloy and silicon form a eutectic alloy. As a result, the plugs are bonded into the apertures or depressions. The composite material can be machined to produce finished devices such as the thermal transfer device. Thermally conductive planes of the thermal pyrolytic graphite plugs may be aligned in parallel to present a thermal conduction path.

Hardesty, Robert E.↗