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An oxide dispersion strengthened Ni-W-Al alloy with superior high temperature strength
An experimental oxide dispersion strengthened (ODS) alloy, WAZ-D, derived from the WAZ-20 composition was produced by the mechanical alloying process. Cast WAZ-20 is strengthened by both a high refractory metal content, and 70 volume percent of gamma prime. The ODS alloy WAZ-D was responsive to variables of alloy content, of attritor processing, of consolidation by extrusion, and of heat treatment. The best material produced had large highly elongated grains. It exhibited tensile strengths generally superior to a comparable cast alloy. The ODS alloy exhibited high temperature stress rupture life considerably superior to any known cast superalloy. Tensile and rupture ductility were low, as was intermediate temperature rupture life. Very low creep rates were noted and some specimens failed with essentially no third stage creep. Also the benefit derived from the oxide dispersion, far out-weighed that from the elongated microstructure alone.
Creep resistance
High-temperature structural applications usually require creep resistance because some average stress is maintained for prolonged periods. Alloy and microstructural design guidelines for creep resistance are presented through established knowledge on creep behavior and its functional dependences on alloy microstructure. Important considerations related to creep resistance of alloys as well as those that are harmful to high-temperature properties are examined. Although most of the creep models do not predict observed creep behavior quantitatively, they are sophisticated enough to provide alloy or microstructural design guidelines. It is shown that creep-resistant microstructures are usually in conflict with microstructures that improve such other properties as stress rupture ductility. Greater understanding of the effects of environments on creep and stress rupture behavior of materials is necessary before one can optimally design alloys for applications in different environments.
Some observations regarding the statistical determination of stress rupture regression lines
Observations concerning the statistical evaluation of creep data are presented. Methods currently employed in the determination of stress rupture regression lines can result in conflicting and necessarily invalid results. Anomalous behavior is principally associated with the selection of the dependent variable. However, it is the least squares method of curve fitting which introduces regression bias. Methods to improve the validity of least squares regressions are suggested.
Orientation dependence of the stress rupture properties of Nickel-base superalloy single crystals
The influence of orientation of the stress rupture behavior of Mar-M247 single crystals was studied. Stress rupture tests were performed at 724 MPa and 774 C where the effect of anisotropy is prominent. The mechanical behavior of the single crystals was rationalized on the basis of the Schmid factors for the operative slip systems and the lattice rotations which the crystals underwent during deformation. The stress rupture lives were found to be greatly influenced by the lattice rotations required to produce intersecting slip, because steady-state creep does not begin until after the onset of intersecting slip. Crystals which required large rotations to become oriented for intersecting slip exhibited a large primary creep strain, a large effective stress level at the onset of steady-state creep, and consequently a short stress rupture life. A unified analysis was attained for the stress rupture behavior of the Mar-M247 single crystals tested in this study at 774 C and that of the Mar-M200 single crystals tested in a prior study at 760 C. In this analysis, the standard 001-011-111 stereographic triangle was divided into several regions of crystallographic orientation which were rank ordered according to stress rupture life for this temperature regime. This plot indicates that those crystals having orientations within about 25 deg of the 001 exhibited significantly longer lives when their orientations were closer to the 001-011 boundary of the stereographic triangle than to the 001-111 boundary.
Alloy design with oxide dispersoids and precipitates
The mechanical behavior of particle-strengthened alloys is reviewed. On the basis of this knowledge, it is concluded that second-phase particles, coherent or incoherent, can enhance the flow strength, creep resistance, and stress-rupture life of alloys. Unfortunately, particles are usually not beneficial alloy-design elements if enhanced uniaxial ductility, plane-strain ductility, stress-rupture ductility, and toughness are called for. Such properties as fatigue-crack propagation resistance appear to require, for example, both high strength and high ductility, a situation which can come to pass only when the perennial conflict between strength and ductility is resolved in particle-strengthened systems in particular and in any other material system in general. Wherever possible, the role of coherent and incoherent particles in alloy design is distinguished.
Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet Molding Compound
Although polyimide based composites have been used for many years in a wide variety of elevated temperature applications, very little work has been done to examine the durability and damage behavior under more prototypical thermomechanical fatigue (TMF) loadings. Synergistic effects resulting from simultaneous temperature and load cycling can potentially lead to enhanced, if not unique, damage modes and contribute to a number of nonlinear deformation responses. The goal of this research was to examine the effects of a TMF loading spectrum, representative of a gas turbine engine compressor application, on a polyimide sheet molding compound (SMC). High performance SMCs present alternatives to prepreg forms with great potential for low cost component production through less labor intensive, more easily automated manufacturing. To examine the issues involved with TMF, a detailed experimental investigation was conducted to characterize the durability of a T650-35/PMR-15 SMC subjected to TMF mission cycle loadings. Fatigue damage progression was tracked through macroscopic deformation and elastic stiffness. Additional properties, such as the glass transition temperature (T(sub g) and dynamic mechanical properties were examined. The fiber distribution orientation was also characterized through a detailed quantitative image analysis. Damage tolerance was quantified on the basis of residual static tensile properties after a prescribed number of TMF missions. Detailed microstructural examinations were conducted using optical and scanning electron microscopy to characterize the local damage. The imposed baseline TMF missions had only a modest impact on inducing fatigue damage with no statistically significant degradation occurring in the measured macroscopic properties. Microstructural damage was, however, observed subsequent to 100 h of TMF cycling which consisted primarily of fiber debonding and transverse cracking local to predominantly transverse fiber bundles. The TMF loadings did introduce creep related effects (strain accumulation) which led to rupture in some of the more aggressive stress scenarios examined. In some cases this creep behavior occurred at temperatures in excess of 150 C below commonly cited values for T(sub g). Thermomechanical exploratory creep tests revealed that the SMC was subject to time dependent deformation at stress/temperature thresholds of 150 MPa/230 C and 170 MPa/180 C.
Creep damage in a cr-mo-v steel as measured by retained stress rupture properties
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Environmental Durability and Stress Rupture of EBC/CMCs
This research focuses on the strength and creep performance of SiC fiber-reinforced SiC ceramic matrix composite (CMC) environmental barrier coating (EBC) systems under complex simulated engine environments. Tensile-strength and stress-rupture testing was conducted to illustrate the material properties under isothermal and thermal gradient conditions. To determine material durability, further testing was conducted under exposure to thermal cycling, thermal gradients and simulated combustion environments. Emphasis is placed on experimental techniques as well as implementation of non-destructive evaluation, including modal acoustic emission and electrical resistivity monitoring, to characterize strength degradation and damage mechanisms. Currently, little is known about the behavior of EBC-CMCs under these conditions; consequently, this work will prove invaluable in the development of structural components for use in high temperature applications.
Effects of fine porosity on the fatigue behavior of a powder metallurgy superalloy
Hot isostatically pressed powder metallurgy Astroloy was obtained which contained 1.4 percent fine porosity at the grain boundaries produced by argon entering the powder container during pressing. This material was tested at 650 C in fatigue, creep fatigue, tension, and stress-rupture and the results compared with previous data on sound Astroloy. The pores averaged about 2 micrometers diameter and 20 micrometers spacing. They did influence fatigue crack initiation and produced a more intergranular mode of propagation. However, fatigue life was not drastically reduced. A large 25 micrometers pore in one specimen resulting from a hollow particle did not reduce life by 60 percent. Fatigue behavior of the porous material showed typical correlation with tensile behavior. The plastic strain range life relation was reduced proportionately with the reduction in tensile ductility, but the elastic strain range-life relation was little changed reflecting the small reduction in sigma sub u/E for the porous material.
Effects of fine porosity on the fatigue behavior of a powder metallurgy superalloy
Hot-isostatically-pressed powder-metallurgy Astroloy was obtained which contained 1.4 percent porosity at the grain boundaries produced by argon entering the powder container during pressing. This material was tested at 650 C in fatigue, creep-fatigue, tension, and stress-rupture and the results compared with data on sound Astroloy. They influenced fatigue crack initiation and produced a more intergranular mode of propagation but fatigue life was not drastically reduced. Fatigue behavior of the porous material showed typical correlation with tensile behavior. The plastic strain range-life relation was reduced proportionately with the reduction in tensile ductility, but the elastic strain range-life relation was changed little.
The effect of tantalum and carbon on the structure/properties of a single crystal nickel-base superalloy
The microstructure, phase chemistry, and creep and hot tensile properties were studied as a function of tantalum and carbon levels in Mar-M247 type single crystal alloys. Microstructural studies showed that several types of carbides (MC, M23C6 and M5C) are present in the normal carbon (0.10 wt % C) alloys after heat treatment. In general, the composition of the MC carbides changes from titanium rich to tantalum rich as the tantalum level in the alloy increases. Small M23C6 carbides are present in all alloys. Tungsten rich M6C carbides are also observed in the alloy containing no tantalum. No carbides are present in the low carbon (0.01 wt % C) alloy series. The morphology of gamma prime is observed to be sensitive to heat treatment and tantalum level in the alloy. Cuboidal gamma prime is present in all the as cast structures. After heat treatment, the gamma prime precipitates tend to have a more spheroidal like morphology, and this tendency increases as the tantalum level decreases. On prolonged aging, the gamma prime reverts back to a cuboidal morphology or under stress at high temperatures, forms a rafted structure. The weight fraction and lattice parameter of the spheroidal gamma prime increases with increasing tantalum content. Changes in the phase chemistry of the gamma prime matrix and gamma prime have also been analyzed using phase extraction techniques. The partitioning ratio decreases for tungsten and aluminum and increases for tantalum as the tantalum content increases for both alloy series; no significant changes occur in the partitioning ratios of the other alloying elements. A reduction in secondary creep rate and an increase in rupture time result from increasing the tantalum content and decreasing the carbon level.
Application of a method of estimating high temperature low cycle fatigue behavior of materials.
High temperature low cycle creep range strain fatigue behavior estimation from tensile and stress rupture properties
Application of a method of estimating high- temperature low-cycle fatigue behavior of materials.
Metal alloys high temperature low cycle strain fatigue resistance in creep range estimated from tensile and stress rupture data
Investigation of Three Analytical Hypothesis for Determining Material Creep Behavior under Varied Loads, with an Application to 2024-T3 Aluminum-Alloy Sheet in Tension at 400 F
Three existing hypotheses are formulated mathematically to estimate tensile creep strain under varied loads and constant temperature from creep data obtained under constant load and constant temperature. hypotheses investigated include the time-hardening, strain-hardening, and life-fraction rules. Predicted creep behavior is compared with data obtained from tensile creep tests of 2024-T3 aluminum-alloy sheet at 400 F under cyclic-load conditions. creep strain under varied loads is presented on the basis of an equivalent stress, derived from the life-fraction rule, which reduces the varied-load case to a constant-load problem. Creep strain in the region of interest for structural design and rupture times, determined from the hypotheses investigated, are in fair agreement with data in most cases, although calculated values of creep strain are generally greater than the experimental values because creep recovery is neglected in the calculations.
Fracture Mechanisms For SiC Fibers And SiC/SiC Composites Under Stress-Rupture Conditions at High Temperatures
The successful application of SiC/SiC ceramic matrix composites as high-temperature structural materials depends strongly on maximizing the fracture or rupture life of the load-bearing fiber and matrix constituents. Using high-temperature data measured under stress-rupture test conditions, this study examines in a mechanistic manner the effects of various intrinsic and extrinsic factors on the creep and fracture behavior of a variety of SiC fiber types. It is shown that although some fiber types fracture during a large primary creep stage, the fiber creep rate just prior to fracture plays a key role in determining fiber rupture time (Monkman-Grant theory). If it is assumed that SiC matrices rupture in a similar manner as fibers with the same microstructures, one can develop simple mechanistic models to analyze and optimize the stress-rupture behavior of SiC/SiC composites for applied stresses that are initially below matrix cracking.
Creep and Environmental Durability of EBC/CMCs Under Imposed Thermal Gradient Conditions
Interest in SiC fiber-reinforced SiC ceramic matrix composite (CMC) environmental barrier coating (EBC) systems for use in high temperature structural applications has prompted the need for characterization of material strength and creep performance under complex aerospace turbine engine environments. Stress-rupture tests have been performed on SiC/SiC composites systems, with varying fiber types and coating schemes to demonstrate material behavior under isothermal conditions. Further testing was conducted under exposure to thermal stress gradients to determine the effect on creep resistance and material durability. In order to understand the associated damage mechanisms, emphasis is placed on experimental techniques as well as implementation of non-destructive evaluation; including electrical resistivity monitoring. The influence of environmental and loading conditions on life-limiting material properties is shown.
Strain accumulation and surface deformation along the San Andreas, California
Stressing and rupture of a locked zone adjacent to a creeping fault segment was studied with special reference to strength heterogeneity depthwise and along-strike. The resulting precursory temporal and spatial variations of surface strain rate profiles were compared to geodetic measurements on the San Andreas fault in central California. Crustal deformation in great California earthquake cycles was also studied with special reference to the temporal decay of strain rate observed since the 1957 and 1906 great earthquakes, and comtemporary surface strain rate and velocity profiles at several locations along the San Andreas. The effect of viscoelastic response in the deep aseismic shear zone on the surface deformation behavior was examined. Work was begun on a fundamental reformulation of the crustal deformation problem focusing on the crustal deformation process affected by deep aseismic slip as the slip zone progresses toward an instability and as deep seismic slip continues postseismically, the 3-D nature of the problem due to geometry and material heterogeneity, and the time-dependent source coming from the lithosphere/astenospheric coupling process.