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Electro-chemical grinding technique has rotation speed control, constant feed rates, and contour control. Hypersonic engine parts of nickel alloys can be almost 100% machined, keeping tool pressure at virtual zero. Technique eliminates galling and permits constant surface finish and burr-free interrupted cutting.
Study of substitutional diffusion in thoriated and nonthoriated nickel alloys, particularly in several nominally Ni-20Cr-2ThO2:Ni type diffusion couples diffused at 1530 K. Upon metallographic examination, one DS-NiCr:Ni couple had negligible Kirkendall pore formation while the other couples contained significant porosity. It is believed that the difference in Kirkendall porosity is related to the unique grain structure of the particular lot of DS-NiCr used in this diffusion couple.
Dispersion-strengthened nickel alloys are sanded on one side and chemically polished. This is followed by a single-step welding process wherein the polished surfaces are forced into intimate contact at 1,400 F for one hour in a vacuum. Diffusion, recrystallization, and grain growth across the original weld interface are obtained during postheating at 2,150 F for two hours in hydrogen.
A region or cap of very fine two-dimensional surface growth structure was observed at the top of three of the six pure nickel flight specimens. Such two-dimensional surface growth structures have been observed both on the ground-based specimens and on other surface areas of the flight specimens. However, the fine structures observed on the three flight samples are at least an order of magnitude finer than those previously observed, and resemble similar localized, fine, two-dimensional surface structures observed in both ground and flight specimens for the nickel alloys. The two-dimensional growth areas consist primarily of fine equiaxed grains, specimen SL-2.6, fine dendrites, specimen SL-2.5, or a core of fine equiaxed grains surrounded by a ring of fine dendrites, specimen SL-1.9.
A radio frequency powered ion plating process was used to apply the diffusion barriers of aluminum oxide, yttrium oxide, hafnium oxide and titanium carbide to a substrate tungsten fiber. Each of the coatings was examined as to its effect on both room temperature strength and tensile strength of the base tungsten fiber. The coated fibers were then overcoated with a nickel alloy to become single cell diffusion couples. These diffusion couples were exposed to 1093 C for 24 hours, cycled between room temperature and 1093 C, and given a thermal anneal for 100 hours at 1200 C. Tensile testing and metallographic examinations determined that the hafnium oxide coating produced the best high temperature diffusion barrier for tungsten of the four coatings.
The sintered aluminum powder (SAP) technique of dispersion strengthening (formation of an oxide dispersion by preoxidation of metal powders) was applied to atomized powder of a nickel alloy containing, by weight, 17% Cr, 5% Al, and 0.2% Y. The SAP-NiCrAl alloy (without the ytterbium removed by oxdation) was worked by extrusion and rod rolling at 1205 C and by swaging at 760 C. Annealing treatments were applied after working to determine the recrystallization response. The NiCrAlY alloy, similarly prepared from atomized powder, but without a preoxidation treatment, was examined for comparison. The SAP-NiCrAl alloy exhibited oxide particle size and spacing much larger than that usually observed in oxide dispersion strengthened alloys; nonetheless, it was possible to achieve abnormal (secondary) recrystallization in the SAP-NiCrAl alloy as has been reported for other oxide dispersion strengthened alloys. In contrast, the unoxidized NiCrAlY alloy exhibited only primary recrystallization.
Research in metallurgical processing to study the effects of reduced gravity started with Apollo 14 and advanced with Skylab. Experiments provided specimens for analysis which solidified while constrained and while freely floating, which contained a mixture of normally immiscible materials, demonstrated enhanced capillary flow, solubility and ordered growth of a directionally solidified eutectic. The smaller, equiaxed grain structure obtained in reduced gravity compared to the larger, elongated grains obtained in one gravity indicate a difference in convection due to gravity in constrained solidification. Freely floating nickel alloy specimens showing metallic gas evolution at low pressure and reduced gravity suggest reduced pressure reactions which cannot occur on earth even in high vacuum chambers due to the hydrostatic head in the molten metal. Directionally solidified eutectics showed fewer termination defects when grown in reduced gravity. These are a few of the differences observed due to reduced gravity which could have important consequences on the future of metallurgy. In this paper we attempt to correlate the results of several Skylab solidification experiments.
Discussed are advancements in wind tunnel model construction methods and hypersonic test data demonstrating the methods. The general objective was to develop model fabrication methods for improved heat transfer measuring capability at less model cost. A plated slab model approach was evaluated with cast models containing constantan wires that formed single-wire-to-plate surface thermocouple junctions with a seamless skin of electroless nickel alloy. The surface of a space shuttle orbiter model was selectively plated with scaled tiles to simulate, with high fidelity, the probable misalignments of the heatshield tiles on a flight vehicle. Initial, Mach 8 heating results indicated a minor effect of tile misalignment roughness on boundary layer transition, implying a possible relaxation of heatshield manufacturing tolerances. Some loss of the plated tiles was experienced when the model was tested at high heating rates.
The purpose of this experiment is to localize celestial sources of X-rays to a precision of 5 to 20 arcsec, so that they may be identified with optical or radio counterparts. We also study their angular size and structure, to elucidate the X-ray emission mechanism. Four grids, wound with nickel alloy wires, are aligned to produce a modulated X-ray signal when the spacecraft rotation carries the collimator field of view across an X-ray source. An image dissector star camera and rate integrating gyroscopes are used to deduce the celestial position from which a peak X-ray signal arises. On-orbit performance and thermal stability have been very good. Based on the first six weeks of quick look data, we have the following results: the location of an X-ray burst source within a globular cluster; the location of 4U1608-52, a unique object which shows bursting, transient, and steady X-ray behavior and is also an optical source; the location of the X-ray transient H1705-25, which provided Anglo-Australian astronomers the basis for an optical identification with a nova-like object; the location of the X-ray transient H1743-32 in the galactic center; and a precise measurement of the angular extent of the Crab Nebula.
Need to reduce wear on nickel alloy seats and poppets for Space Shuttle main engine led to fused cobalt/tungsten carbide coating. Coating, which is dense, wear-resistant, and nonporous, can be applied in controlled amounts to various substrate configurations. Ease of application to parts with intricate shapes and contours should make coating useful in automotive and aircraft manufacturing.
The thermodynamics of graphite, carbide, and carbonate formation in the presence of a solar-composition gas is examined, including the feasibility of producing solid solutions of carbon and carbides in metallic iron-nickel alloy. Gas-phase composition and graphite activities for a very wide range of nebular pressures and temperatures are calculated by a computer program that considers several hundred compounds, particularly all the important gaseous species containing H, C, O, N, S, Cl, P, and F. The results obtained indicate that CH4 and CO would be the dominant carbon compounds under all likely circumstances of temperature and pressure in the solar nebula, that graphite may have been the most abundant carbon species in certain cases, and that direct precipitation of graphite, carbides, or carbonates would have been impossible in the solar nebula. Carbon retention by the terrestrial planets is also investigated.
Nickel-alloy precoat applied with plasmagun improves adhesion of ceramic materials applied to protect areas from unintentional brazing. Metal surface should be grit-blasted before precoating. Coating does not interfere with brazing or contaminate vacuum pumping systems.
An endothermically heated technology was used to manufacture low cost, directionally solidified, uncooled nickel-alloy blades for the TFE731-3 turbofan engine. The MAR-M 247 and MER-M 100+Hf blades were finish processed through heat treatment, machining, and coating operations prior to 150 hour engine tests consisting of the following sequences: (1) 50 hours of simulated cruise cycling (high fatigue evaluation); (2) 50 hours at the maximum continuous power rating (stress rupture endurance (low cycle fatigue). None of the blades visually showed any detrimental effects from the test. This was verified by post test metallurgical evaluation. The specific fuel consumption was reduced by 2.4% with the uncooled blades.
Magnetic properties of small iron-nickel alloy spheres, having compositions which cover the entire Fe-Ni binary, are presented. The spheres were formed during solidification in free fall following the melting of electropolished wires of appropriate composition. The spheres with Ni not greater than 25% acquired a martensitic thermal remanence while those with Ni not less than 30% acquired a thermoremanent magnetization. A magnetic remanence-composition diagram and a coercive force-composition diagram are constructed. Magnetic hysteresis loops and derived parameters demonstrate the difference between metal-bearing and oxide-bearing natural samples. The magnetic remanence varies as the sphere size in conjunction with the microstructure. These results help to explain why coercive force is generally low, remanent coercive force is generally high, and their ratio (R/C) is always large in fine metal dispersions, such as lunar samples and chondrite meteorites.
Solutions that etch some corrosion-resistant metals described in test report. Etchants selected remove at least 0.4 mil of surface material per hour from nickel alloys, austenitic stainless steel, and annealed titanium alloys, without intergranular attack.
Spiking in electron-beam welding reduced by placing high-vapor-pressure substance along path of electron beam. Strip of metal having vapor pressure higher than base metal at same temperature placed in slot machined along weld line. Strip vaporizes as beam strikes it, and vapor pressure keeps surface tension from closing off top of channel. Technique used successfully on nickel alloys and aluminum alloys and effective on steel and titanium.
Thin platinum film on thermocouple sheath protects non-noble-metal thermocouples from deterioration in oxygen-rich atmosphere. Coating works on nickel-alloy sheathed thermocouples otherwise destroyed by corrosion in pure oxygen at 1,000 degrees C.
Hot forming to restore size and shape of thin metal parts done with electron-beam welder. Work-piece heated in scanning defocused electron beam rather than conventional heat-treating furnace. Technique proved successful in straightening some thin flanges of nickel alloy and titanium.