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At least 307 records · Page 17

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DOE OSTI2021

Shear Assisted Processing and Extrusion of Aluminum Alloy 7075 Tubing at High Speed

Conventional extrusion of aluminum alloy 7075 is limited to 1-2 meters per minute in order to avoid surface tearing and cracking. An emerging technique called Shear Assisted Processing and Extrusion (ShAPE) was used to extrude aluminum alloy 7075 tubing at a speed of 7.4 meters per minute without inducing surface defects. The faster extrusion speed is attributed to the unique flow characteristics inherent to the ShAPE process compared to conventional extrusion. Tubes with an inner diameter of 10 mm, outer diameter of 12 mm, and length of 2 meters were extruded at temperatures ranging from 340°C to 466°C. Tensile testing was performed per ASTM B557-15 with strain measured using digital image correlation. An ultimate tensile strength of 565 ± 4.6 MPa, yield strength of 496 ± 8.7 MPa, and elongation of 16.4 ± 1.0 % were measured for extrusion made at 362°C and heat treated to the T6 condition.

Shear Assisted Processing and Extrusion, Friction ↗

DOE OSTI2025

Analysis Of Fracture Location on Tensile Graphite Samples

The main standard for testing the ultimate tensile strength of graphite is ASTM C749. Commercial entities have raised concerns about samples breaking outside of the gauge section, particularly in the radius or head of the sample. When this occurs, the data gathered from the samples is unusable and increases the cost of testing as more samples will need to be machined. This study investigates the locations and frequency of sample breakage for four different grades of graphite using a custom-made measurement scale. The four grades include two fine-grain (2114 and IG-110) and two medium/coarse-grain (NBG-17 and PCEA). Our results show that fine-grain grades are more susceptible to breaking outside the gauge section, with almost 30% of the samples from grade 2114 breaking outside this region. Additionally, the radius being too small causes stress concentrations near the ends of the gauge section resulting in a bimodal distribution of the fracture locations.

36 - MATERIALS SCIENCE↗

NASA NTRS1993

Back Propagation Neural Networks for Predicting Ultimate Strengths of Unidirectional Graphite/Epoxy Tensile Specimens

The research presented herein demonstrates the feasibility of predicting ultimate strengths in simple composite structures through a neural network analysis of their acoustic emission (AE) amplitude distribution data. A series of eleven ASTM D-3039 unidirectional graphite/epoxy tensile samples were loaded to failure to generate the amplitude distributions for this analysis. A back propagation neural network was trained to correlate the AE amplitude distribution signatures generated during the first 25% of loading with the ultimate strengths of the samples. The network was trained using two sets of inputs: (1) the statistical parameters obtained from a Weibull distribution fit of the amplitude distribution data, and (2) the event frequency (amplitude) distribution itself. The neural networks were able to predict ultimate strengths with a worst case error of -8.99% for the Weibull modeled amplitude distribution data and 3.74% when the amplitude distribution itself was used to train the network. The principal reason for the improved prediction capability of the latter technique lies in the ability of the neural network to extract subtle features from within the amplitude distribution.

Walker, James L.↗

NASA NTRS2013

The Effect of Scale Dependent Discretization on the Progressive Failure of Composite Materials Using Multiscale Analyses

A multiscale modeling methodology, which incorporates a statistical distribution of fiber strengths into coupled micromechanics/ finite element analyses, is applied to unidirectional polymer matrix composites (PMCs) to analyze the effect of mesh discretization both at the micro- and macroscales on the predicted ultimate tensile (UTS) strength and failure behavior. The NASA code FEAMAC and the ABAQUS finite element solver were used to analyze the progressive failure of a PMC tensile specimen that initiates at the repeating unit cell (RUC) level. Three different finite element mesh densities were employed and each coupled with an appropriate RUC. Multiple simulations were performed in order to assess the effect of a statistical distribution of fiber strengths on the bulk composite failure and predicted strength. The coupled effects of both the micro- and macroscale discretizations were found to have a noticeable effect on the predicted UTS and computational efficiency of the simulations.

Ricks, Trenton M.↗

NASA NTRS1988

High-temperature properties of ceramic fibers and insulations for thermal protection of atmospheric entry and hypersonic cruise vehicles

Multilayer insulations (MIs) which will operate in the 500 to 1000 C temperature range are being considered for possible applications on aerospace vehicles subject to convective and radiative heating during atmospheric entry. The insulations described consist of ceramic fibers, insulations, and metal foils quilted together with ceramic thread. As these types of insulations have highly anisotropic properties, the total heat transfer characteristics must be determined. Data are presented on the thermal diffusivity and thermal conductivity of four types of MIs and are compared to the baseline Advanced Flexible Reusable Surface Insulation currently used on the Space Shuttle Orbiter. In addition, the high temperature properties of the fibers used in these MIs are discussed. The fibers investigated included silica and three types of aluminoborosilicate (ABS). Static tension tests were performed at temperatures up to 1200 C and the ultimate strain, tensile strength, and tensile modulus of single fibers were determined.

Kourtides, Demetrius A.↗

NASA NTRS1988

High temperature properties of ceramic fibers and insulations for thermal protection of atmospheric entry and hypersonic cruise vehicles

Kourtides, Demetrius A.↗

NASA NTRS1988

A study of thermal transitions in a new semicrystalline thermoplastic polyimide

A polyimide derive from 4,4'-isophthaloyl diphthalic anhydride (IDPA) and 1,3-bis (4-aminophenoxy 4'-benzoyl) benzene (1,3-BABB) having semicrystalline behavior was prepared and characterized by differential scanning calorimetry (DSC) and wide angle X-ray scattering (WAXS). Thus a poly(amic acid) film cured in air for one hour each at 100 and 200 C displayed an endotherm at 286 C, followed by a crystallization exotherm at 317 C, and a second melting transition at 350 C. The 286 C melting point appeared to result from earlier solvent-induced crystallization. Films cast from DMAc, air dried, and soaked in methylene chloride could not be induced into semicrystallinity. The fully cured polyimide has a Tg of 216 C. Films heated to temperatures as high as 100 C for one hour in air were transparent and light yellow in color. Those films heated to or above 125 C were translucent. Polarized light microscopy revealed the presence of spherulites 608 micrometers in diameter in a sample cured to 275 C in air. Two film samples, one cured to 275 and the other to 325 C, were evaluated for tensile and ultimate strength, modulus, and percent elongation at 25 and 200 C. These values remained essentially constant at each test temperature.

Pratt, J. Richard↗

NASA NTRS1982

Strength of Rewelded Inconel 718

Inconel 718, nickel-based alloy used extensively for high-temperature structural service, welded repeatedly without detriment to its strength. According to NASA report, tests show 12 repairs on same weld joint do not adversely affect ultimate tensile strenth, yield strength, fatigue strength, metallurgical grain structures, or ability of weld joint to respond to post weld heat treatments.

Bayless, E.↗

NASA NTRS1978

Hydrogen attack - Influence of hydrogen sulfide

An experimental study is conducted on 12.5-mm-thick SAE 1020 steel (plain carbon steel) plate to assess hydrogen attack at room temperature after specimen exposure at 525 C to hydrogen and a blend of hydrogen sulfide and hydrogen at a pressure of 3.5 MN/sq m for exposure times up to 240 hr. The results are discussed in terms of tensile properties, fissure formation, and surface scales. It is shown that hydrogen attack from a high-purity hydrogen environment is severe, with the formation of numerous methane fissures and bubbles along with a significant reduction in the room-temperature tensile yield and ultimate strengths. However, no hydrogen attack is observed in the hydrogen/hydrogen sulfide blend environment, i.e. no fissure or bubble formation occurred and the room-temperature tensile properties remained unchanged. It is suggested that the observed porous discontinuous scale of FeS acts as a barrier to hydrogen entry, thus reducing its effective equilibrium solubility in the iron lattice. Therefore, hydrogen attack should not occur in pressure-vessel steels used in many coal gasification processes.

Eliezer, D.↗

NASA NTRS1991

Temperature effects on high strain rate properties of graphite/epoxy composites

A unidirectional graphite epoxy material (AS4/3501-6) was characterized at strain rates ranging from 5 x 10(exp 6) s(exp -1) to 5(exp -1), at room temperature and at 128 C. Results are presented in the form of stress-strain curves to failure. The longitudinal properties remain nearly unchanged with strain rate and temperature. The transverse modulus increases with strain rate but decreases with temperature. The transverse strength and transverse ultimate tensile strain have a positive rate sensitivity at low rates, which changes to negative at intermediate rates and returns to positive rate sensitivity at the highest rates tested. A temperature-time equivalence principle was applied and master curves were obtained for the transverse mechanical properties. The in-plane shear modulus and in-plane shear strength have a positive rate sensitivity. The ultimate intralaminar shear strain has a positive rate sensitivity at low rates, which changes to negative at high rates. At the elevated temperature of 128 C, the ultimate shear strain is 25 to 30 percent higher than the room temperature value, but its strain rate dependence is moderate.

Yaniv, G.↗

DOE OSTI2024

Wire arc additive manufactured A36 steel performance for marine renewable energy systems

Additive manufacturing has established itself to be advantageous beyond small-scale prototyping, now supporting full-scale production of components for a variety of applications. Despite its integration across industries, marine renewable energy technology is one largely untapped application with potential to bolster clean energy production on the global scale. Wave energy converters (WEC) are one specific facet within this realm that could benefit from AM. As such, wire arc additive manufacturing (WAAM) has been identified as a practical method to produce larger scale marine energy components by leveraging cost-effective and readily available A36 steel feedstock material. The flexibility associated with WAAM can benefit production of WEC by producing more complex structural geometries that are challenging to produce traditionally. Additionally, for large components where fine details are less critical, the high deposition rate of WAAM in comparison to traditional wrought techniques could reduce build times by an order of magnitude. In this context of building and supporting WEC, which experience harsh marine environments, an understanding of performance under large loads and corrosive environments must be understood. Hence, WAAM and wrought A36 steel tensile samples were manufactured, and mechanical properties compared under both dry and corroded conditions. Here, the unique microstructure created via the WAAM process was found to directly correlate to the increased ultimate tensile and yield strength compared to the wrought condition. Static corrosion testing in a simulated saltwater environment in parallel with electrochemical testing highlighted an outperformance of corroded WAAM A36 steel than wrought, despite having a slighter higher corrosion rate. Ultimately, this study shows how marine energy systems may benefit from additive manufacturing components and provides a foundation for future applications of WAAM A36 steel.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Laser Powder Bed Fusion of ODS 14YWT from Gas Atomization Reaction Synthesis Precursor Powders

Abstract Laser powder bed fusion (LPBF) additive manufacturing (AM) is a promising route for the fabrication of oxide dispersion strengthened (ODS) steels. In this study, 14YWT ferritic steel powders were produced by gas atomization reaction synthesis (GARS). The rapid solidification resulted in the formation of stable, Y-containing intermetallic Y 2 Fe 17 on the interior of the powder and a stable Cr-rich oxide surface. The GARS powders were consolidated with LPBF. Process parameter maps identified a stable process window resulting in a relative density of 99.8%. Transmission electron microscopy and high-energy x-ray diffraction demonstrated that during LPBF, the stable phases in the powder dissociated in the liquid melt pool and reacted to form a high density (1.7 × 10 20 /m 3 ) of homogeneously distributed Ti 2 Y 2 O 7 pyrochlore dispersoids ranging from 17 to 57 nm. The use of GARS powder bypasses the mechanical alloying step typically required to produce ODS feedstock. Preliminary mechanical tests demonstrated an ultimate tensile and yield strength of 474 MPa and 312 MPa, respectively.

36 MATERIALS SCIENCE↗

NASA NTRS1972

ZM-21 magnesium alloy corrosion properties and cryogenic to elevated temperature mechanical properties

The mechanical properties of bare ZM-21 magnesium alloy flat tensile specimens were determined for test temperatures of +400 F, +300 F, +200 F, +80 F, 0 F, -100 F, -200 F, and -320 F. The ultimate tensile and yield strengths of the material increased with decreasing temperature with a corresponding reduction in elongation values. Stress corrosion tests performed under: (1) MSFC atmospheric conditions; (2) 95% relative humidity; and (3) submerged in 100 ppm chloride solution for 8 weeks indicated that the alloy is not susceptible to stress corrosion. The corrosion tests indicated that the material is susceptible to attack by crevice corrosion in high humidity and chemical type attack by chloride solution. Atmospheric conditions at MSFC did not produce any adverse effects on the material, probably due to the rapid formation of a protective oxide coating. In both the mechanical properties and the stress corrosion evaluations the test specimens which were cut transverse to the rolling direction had superior properties when compared to the longitudinal properties.

Montana, J. W.↗

NASA NTRS1976

The Stress Corrosion Resistance and the Cryogenic Temperature Mechanical Behavior of 18-3 Mn (Nitronic 33) Stainless Steel Parent and Welded Material

The ambient and cryogenic temperature mechanical properties and the ambient temperature stress corrosion results of 18-3 Mn (Nitronic 33)stainless steel, longitudinal and transverse, as received and as welded (TIG) material specimens manufactured from 0.063 inch thick sheet material, were described. The tensile test results indicate an increase in ultimate tensile and yield strengths with decreasing temperature. The elongation remained fairly constant to -200 F, but below that temperature the elongation decreased to less than 6.0% at liquid hydrogen temperature. The notched tensile strength (NTS) for the parent metal increased with decreasing temperature to liquid nitrogen temperature. Below -320 F the NTS decreased rapidly. The notched/unnotched (N/U) tensile ratio of the parent material specimens remained above 0.9 from ambient to -200 F, and decreased to approximately 0.65 and 0.62, respectively, for the longitudinal and transverse directions at liquid hydrogen temperature. After 180 days of testing, only those specimens exposed to the salt spray indicated pitting and some degradation of mechanical properties.

Montano, J. W.↗

NASA NTRS1978

Microstructure and mechanical properties of quenched and tempered 300M steel

Type 300M steel, which is being used for the landing gear on the space shuttle orbiter, was subjected to a wide range of quenched and tempered heat treatments. The plane-strain fracture toughness and the tensile ultimate and yield strengths were evaluated. Cryogenic mechanical properties were obtained for conventionally heat-treated steel. The microstructure of all heat-treated test coupons was studied both optically and by transmission electron microscopy. Fracture surfaces were studied by means of scanning electron microscopy. Results indicate that substantial improvement in toughness with no loss in strength can be accomplished in quenched and tempered steel by austenitizing at 1255 K or higher. Low fracture toughness in conventionally austenitized 300M steel (1144 K) appears to be caused by undissolved precipitates, seen both in the submicrostructure and on the fracture surface, which promote failure by quasi-cleavage. The precipitates appeared to dissolve in the range 1200 to 1255 K.

Youngblood, J. L.↗

NASA NTRS2003

Characterization of a Ultra-high Temperature Ceramic Composite

Ultra-high temperature ceramics (UHTC) are of interest for hypersonic vehicle leading edge applications. Monolithic UHTCs are of concern because of their low fracture toughness and brittle behavior. UHTC composites (UHTCC) are being investigated as a possible approach to overcome these deficiencies. In this study a small sample of a UHTCC was evaluated by limited mechanical property tests, furnace oxidation exposures, and oxidation exposures in a flowing environment. The composite was prepared from a carbon fiber perform using ceramic particulates and a preceramic polymer. The as-received composite plate was non-uniform from front to back surface. Plate dimensions were 150 x 150 x 6 mm. The back surface had a fibrous, uniform appearance; XRD analysis revealed the presence of Sic and C. The front surface was smooth and non-uniform in appearance with evidence of a coarse grain structure produced by a liquid phase; XRD analysis revealed the presence of HfB2. Microcracks were present throughout the thickness as one might expect from a carbon fiber reinforced composite with attendant large thermal expansion mismatch between the matrix phases and the fibers. The HfB2 phase on the front surface was comparable in thickness to a fiber ply or about 0.6 mm, and surface microcracks were evident. Limited four point flexural tests were carried out at span to depth ratios of approximately 14 and 16 with markedly different results. Tests were run with the front or the back surface in tension. At the shorter span to depth failures occurred under a loading pin for both orientations. At a span to depth of 16 failures occurred in the center of the span with fracture clearly initiating from a tensile failure. Ultimate flexural strength, strain at ultimate stress, stress and strain at deviation from linear elastic behavior are reported. Strains at ultimate stress ranged from about 0.6 to 0.7 % for the back surface in tension, and 0.4 to 0.6 for the front surface in tension. At constant span to depth the strain at ultimate stress was about 0.2% greater for the back surface in tension and the ultimate strength was also higher. Strengths were in line with predictions from theory. Furnace oxidation studies were carried out at 1627 and 1927OC in a static furnace environment using ten minute cycles and one, five, and ten cycles. Limited oxidation studies were also carried out in a flowing oxyacetylene torch environment. Specimens were photographed, and weight and dimensional changes were determined. XRD and SEM characterizations were performed. Weight losses were attributed primarily to carbon fiber oxidation. The composite survived the torch test with little visible distress. Further details will be determined once metallographic studies are completed.

Levine, Stanley R.↗

NASA NTRSDate not supplied

Microstructure and Mechanical Properties of Additively Manufactured Haynes 282: A Comparative Analysis between L-PBF and LP-DED Technologies

This study compares the microstructure and tensile properties of Haynes 282 fabricated using laser powder bed fusion and laser powder directed energy deposition. Both sets underwent stress-relieving, followed by hot isostatic pressing, and the standard double aging heat treatment. Tensile testing was conducted at room temperature on specimens fabricated with both technologies to evaluate and compare their tensile behaviors. Results show that the ultimate tensile and yield strengths of laser powder bed fused specimens were 18% and 57% higher, respectively than those of laser powder directed energy deposited ones, whereas the elongation to failure was similar in both. The difference in strengths is attributed to the differences in the size of ɣ' precipitates and grains, i.e., those in the LP-DED specimens being larger, whereas similar elongation to failure is attributed to the carbide debonding dominating the fracture mechanism in both batches.

Additive manufacturing↗

NASA NTRSDate not supplied

Effect of Heat Treatments on the Tensile Properties of Additively Manufactured 15-5 Ph Stainless Steel

This study investigated the effect of post-manufacture heat treatments on the microstructure and mechanical properties of 15-5 PH stainless steel (SS) fabricated by laser powder-directed energy deposition (LP-DED). Various heat treatment procedures (CA-H900 and CA-H1150) were conducted to evaluate their effects on the tensile behavior of LP-DED 15-5 PH SS. Scanning electron microscopy was used to characterize the microstructural features and the fracture surfaces. Tensile tests were performed to evaluate the mechanical properties at cryogenic and room temperatures. Reduction in area of CA-H1150 treated specimens after tensile tests was significantly higher than CA-H900 ones, while the ultimate tensile and yield strengths of CA-H900 specimens were higher compared to the CA-H1150 ones. The mechanical behavior of the LP-DED 15-5 PH SS in various heat treatment conditions is discussed based on their microstructures and fracture surfaces.

Laser powder directed energy deposition (LP-DED)↗