Results for “Ductile material” — Page 17

NASA NTRS1982

Intermetallics as alternative materials

Aluminum containing intermetallics have B2 cubic crystal structures, exist over a wide range of composition, have large solubilities for third element alloying additions, are capable of both low and high temperature plastic flow, and have very high melting temperatures (approximately 1900 K) except for FeAl. The slow strain rate elevated temperature properties of Fe, Ni, and Co aluminides are investigated. Because of the reported difficulties with traditional melting/casting methods, sound polycrystalling materials are fabricated by hot extrusion of steel canned blended prealloyed powders. These binary aluminides are used to develop base line elevated temperature mechanical properties as well as an understanding of the factors which affect/control the strength and ductility.

Whittenberger, J. D.↗

NASA NTRS2015

NASA-427: A New Aluminum Alloy

NASA's Marshall Space Flight Center researchers have developed a new, stronger aluminum alloy, ideal for cast aluminum products that have powder or paint-baked thermal coatings. With advanced mechanical properties, the NASA-427 alloy shows greater tensile strength and increased ductility, providing substantial improvement in impact toughness. In addition, this alloy improves the thermal coating process by decreasing the time required for heat treatment. With improvements in both strength and processing time, use of the alloy provides reduced materials and production costs, lower product weight, and better product performance. The superior properties of NASA-427 can benefit many industries, including automotive, where it is particularly well-suited for use in aluminum wheels.

Nabors, Sammy A.↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Woven↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Discrete Element Method↗

NASA NTRS1971

Investigation of high temperature fracture of T-111 and ASTAR-811C

The high temperature deformation and fracture behavior of T-111 and ASTAR-811C were studied over the temperature range 982 to 2205 C (1800 to 4000 F). As-cast and wrought-recrystallized material as well as GTA welds in sheet and plate were evaluated using conventional tensile and creep tests. Post test examinations were performed using optical metallography, scanning electron microscopy and transmission electron microscopy. A high temperature region of reduced ductility, in terms of tensile elongation, was identified for both alloys. The reduction in tensile elongation became more severe with increase in grain size, being near catastrophic for the as-cast specimens. Optical and electron metallography indicated that even for failures at very low total strain, considerable deformation of a very localized nature had occurred prior to fracture.

Gold, R. E.↗

NASA NTRS2003

Metal Cutting Theory and Friction Stir Welding Tool Design

Friction Stir Welding (FSW) is a relatively new industrial process that was invented at The Weld Institute (TWI, United Kingdom) and patented in 1992 under research funded by in part by the National Aeronautics and Space Administration (NASA). Often quoted advantages of the process include good strength and ductility along with minimization of residual stress and distortion. Less well advertised are the beneficial effects of this solid state welding process in the field of occupational and environmental safety. It produces superior weld products in difficult to weld materials without producing any toxic fumes or solid waste that must be controlled as hazardous waste. In fact, it reduces noise pollution in the workspace as well. In the early days of FSW, most welding was performed on modified machine tools, in particular on milling machines with modified milling cutters. In spite of the obvious milling heritage of the process, the techniques and lessons learned from almost 250 years of successful metalworking with milling machines have not been applied in the field of modern Friction Stir Welding. The goal of the current research was to study currently successful FSW tools and parameterize the process in such a way that the design of new tools for new materials could be accelerated. Along the way, several successful new tooling designs were developed for current issues at the Marshall Space Flight Center with accompanying patent disclosures

Payton, Lewis N.↗

NASA NTRS2010

Empirical Method to Estimate Hydrogen Embrittlement of Metals as a Function of Hydrogen Gas Pressure at Constant Temperature

High pressure Hydrogen (H) gas has been known to have a deleterious effect on the mechanical properties of certain metals, particularly, the notched tensile strength, fracture toughness and ductility. The ratio of these properties in Hydrogen as compared to Helium or Air is called the Hydrogen Environment Embrittlement (HEE) Index, which is a useful method to classify the severity of H embrittlement and to aid in the material screening and selection for safety usage H gas environment. A comprehensive world-wide database compilation, in the past 50 years, has shown that the HEE index is mostly collected at two conveniently high H pressure points of 5 ksi and 10 ksi near room temperature. Since H embrittlement is directly related to pressure, the lack of HEE index at other pressure points has posed a technical problem for the designers to select appropriate materials at a specific H pressure for various applications in aerospace, alternate and renewable energy sectors for an emerging hydrogen economy. Based on the Power-Law mathematical relationship, an empirical method to accurately predict the HEE index, as a function of H pressure at constant temperature, is presented with a brief review on Sievert's law for gas-metal absorption.

Lee, Jonathan A.↗

NASA NTRS1999

Single-Crystal NiAl-X Alloys Tested for Hot Corrosion

Single-crystal nickel aluminide (NiAl) has been investigated extensively throughout the last several years as a potential structural material in aero-gas turbine engines. The attractive features of NiAl in comparison to Ni-base superalloys include a higher melting point, lower density, higher thermal conductivity, and excellent oxidation resistance. However, NiAl suffers from a lack of ductility and fracture toughness at low temperatures and a low creep strength at high temperatures. Alloying additions of hafnium (Hf), gallium (Ga), titanium (Ti), and chromium (Cr) have each shown some benefit to the mechanical properties over that of the binary alloy. However, the collective effect of these alloying additions on the environmental resistance of NiAl-X was unclear. Hence, the present study was undertaken to examine the hot corrosion behavior of these alloys. A companion study examined the cyclic oxidation resistance of these alloys. Several single-crystal NiAl-X alloys (where X is Hf, Ti, Cr, or Ga) underwent hot corrosion testing in a Mach 0.3 burner rig at the NASA Lewis Research Center. Samples were tested for up to 300 1-hr cycles at a temperature of 900 C. It was found that increasing the Ti content from 1 to 5 at.% degraded the hot corrosion behavior. This decline in the behavior was reflected in high weight gains and large corrosion mound formation during testing (see the figures). However, the addition of 1 to 2 at.% Cr to alloys containing 4 to 5 at.% Ti appeared to greatly reduce the susceptibility of these alloys to hot corrosion attack and negated the deleterious effect of the increased Ti addition.

Nesbitt, James A.↗

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 NTRS1993

Use of photostress and strain gages to analyze behavior of weldments and use of photostress and strain gages to analyze behavior of an aft skirt test specimen

Previous work using Photostress on TIG welded, heat treated specimens of 2219-T87 parent material and 2319 weld material indicated that behavior of the joint can be highly irregular and non-uniform. Welded joints 1.40 inches thick exhibited a totally non-uniform behavior through the weld thickness with the 'wide' side of the weld being much more ductile than the 'narrow' side. It is believed that this difference in behavior through the weld is, in part, caused by procedures used when laying the weld bead. Joints similar to weldments in references 1 and 2 are an integral part of the aft skirt of the SRB of the shuttle. Since the ultimate safety factor for the lower portion of the weld is below the minimum required safety factor, a photostress analysis of this lower portion will be conducted in the vicinity of the weld. A test program using photostress will be conducted in accordance with the project planning document entitled 'Photostress Evaluation Requirements for AFT Skirt Test Article No. 4'.

Gambrell, S. C.↗

NASA NTRS1985

Nondestructive techniques for characterizing mechanical properties of structural materials: An overview

An overview of nondestructive evaluation (NDE) is presented to indicate the availability and application potentials of techniques for quantitative characterization of the mechanical properties of structural materials. The purpose is to review NDE techniques that go beyond the usual emphasis on flaw detection and characterization. Discussed are current and emerging NDE techniques that can verify and monitor entrinsic properties (e.g., tensile, shear, and yield strengths; fracture toughness, hardness, ductility; elastic moduli) and underlying microstructural and morphological factors. Most of the techniques described are, at present, neither widely applied nor widely accepted in commerce and industry because they are still emerging from the laboratory. The limitations of the techniques may be overcome by advances in applications research and instrumentation technology and perhaps by accommodations for their use in the design of structural parts.

Vary, A.↗

NASA NTRS1986

Nondestructive techniques for characterizing mechanical properties of structural materials - An overview

An overview of nondestructive evaluation (NDE) is presented to indicate the availability and application potentials of techniques for quantitative characterization of the mechanical properties of structural materials. The purpose is to review NDE techniques that go beyond the usual emphasis on flow detection and characterization. Discussed are current and emerging NDE techniques that can verify and monitor entrinsic properties (e.g., tensile, shear, and yield strengths; fracture toughness, hardness, ductility; elastic moduli) and underlying microstructural and morphological factors. Most of the techniques described are, at present, neither widely applied nor widely accepted in commerce and industry because they are still emerging from the laboratory. The limitations of the techniques may be overcome by advances in applications research and instrumentation technology and perhaps by accommodations for their use in the design of structural parts.

Vary, A.↗

NASA NTRS1998

Improved Electroformed Structural Copper and Copper Alloys

Electroforming offers a superior means for fabricating internally cooled heat exchangers and structures subjected to thermal environments. Copper is deposited from many such applications because of the good thermal conductivity. It suffers from mediocre yield strength as a structural material and loses mechanical strength at intermediate temperatures. Mechanical properties similar to those of electroformed nickel are desired. Phase 1 examined innovative means to improve deposited copper structural performance. Yield strengths as high as 483 MPa (70 ksi) were obtained with useful ductility while retaining a high level of purity essential to good thermal conductivity. Phase 2 represents a program to explore new additive combinations in copper electrolytes to produce a more fine, equiaxed grain which can be thermally stabilized by other techniques such as alloying in modest degrees and dispersion strengthening. Evaluation of new technology - such as the codeposition of fullerness (diamond-like) particles were made to enhance thermal conductivity in low alloys. A test fire quality tube-bundle engine was fabricated using these copper property improvement concepts to show the superiority of the new coppers and fabrications methods over competitive technologies such as brazing and plasma deposition.

Malone, G. A.↗

NASA NTRS2022

Friction Stir Welded Aluminum-Lithium (Al-Li) 2050 Blanks for Spin Forming

Spin forming is a metalworking process used to produce axially-symmetric parts by the application of lateral pressure from a forming tool to a circular blank mounted on a revolving, heated mandrel. This process enables production of cones, domes, or caps that can incorporate features such as flat bulkheads. Friction stir welded (FSW) Al-Li 2195 blanks have been spin formed for single-piece, launch vehicle domes up to 5 m in diameter. Al-Li 2050 plate has the advantage of availability up to 165 mm thick,whereas 2195 plate is traditionally only available up to 57 mm thick. Increased plate thickness enables greater design flexibility for machining of taller structural elements, such as stiffeners. However, 2050 is only available in plate widths up to ~3.9 m. This study demonstrated the capability of making custom 2050 blanks for spin forming large (>7.8 m in diameter), single-piece, light-weight flight articles (e.g., lunar habitats and landers) by FSW two (or more) plates together. Spin forming of welded 2050 blanks has not been attempted before this investigation. The objective was to evaluate the mechanical properties of 2050 parent material and FSW regions after spin forming and subsequent T6 heat treatment. A 3 m diameter x 38 mm thick 2050 blank was fabricated from two 1.5 m wide pieces by FSW and subsequently spin formed into a cone article. Additionally, three 1.2 m diameter x 8.1 mm thick 2050 blanks were produced by FSW and spin formed into subscale cone articles with varying strain input. Mechanical properties are reported for spin formed 2050-T6 parent material and FSW regions on the articles. Abnormal grain growth (AGG) in the FSW during heat treatment was expected based on prior experience with 2195. Implementation of an AGG suppression strategy during heat treatment reduced AGG in the FSW regions and improved ductility.

Spin forming↗

NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

NASA NTRS1977

The promise of eutectics for aircraft turbines

Gas turbine blades and vanes for the 1980s call for new materials with higher operational temperature capabilities. The potential increase of from 40 to 110 C in operational temperature capabilities predicted for directionally solidified eutectics is a larger increment over currently available alloys than previously obtained in any new turbine blade alloy. The paper discusses the properties of gamma/gamma prime-delta and NiTaC-13 directionally solidified first-generation eutectics for use as gas turbine blade materials. A few of the more promising second-generation eutectics for blade applications (gamma/gamma prime-alpha, NiTaC 3-116A) and for vane applications (gamma-beta, COTAC 74) are also discussed. Attention is given to mechanical properties, such as transverse ductility and shear strength, that can be inherently critical in a directionally solidified eutectic. Further R&D requirements for properties, coatings, and lower cost processing technology are identified.

Gray, H. R.↗

NASA NTRS1989

Cryogenic mechanical properties of low density superplastically formable Al-Li alloys

The aerospace industry is considering the use of low density, superplastically formable (SPF) materials, such as Al-Li alloys in cryogenic tankage. SPF modifications of alloys 8090, 2090, and 2090+In were tested for strength and Kahn tear toughness. The results were compared to those of similar tests of 2219-T87, an alloy currently used in cryogenic tankage, and 2090-T81, a recently studied Al-Li alloy with exceptional cryogenic properties (1-9). With decreasing temperature, all materials showed an increase in strength, while most materials showed an increase in elongation and decrease in Kahn toughness. The indium addition to 2090 increased alloy strength, but did not improve the strength-toughness combination. The fracture mode was predominantly intergranular along small, recrystallized grains, with some transgranular fracture, some ductile rupture, and some delamination on large, unrecrystallized grains.

Verzasconi, S. L.↗