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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Metallurgical and mechanical characterization of ATP-5 aluminum alloys for minimizing machining distortion

ATP-5 aluminum alloy was considered as an alternative to 6061-T651 aluminum alloy to minimize machining distortion. ATP-5 is a proprietary cast alloy that is compositionally similar to 5083 aluminum and is purported to have excellent machinability, stability, and corrosion response. Dimensional stability tests, mechanical testing, chemical analysis, microstructural analysis, and fractography were completed to understand the metallurgy of the ATP-5 alloy and assess its potential as a 6061-T651 alloy alternative. Ultimately, the ATP-5 was found to retain dimensional stability issues, albeit to a lesser extent, relative to the 6061-T651 alloy. Combined with the residual cast structure observed microstructurally and lot-to-lot mechanical property variation, the alloy was deemed not suitable for a structural application. Alternative uses of ATP-5 include tooling, molds, vacuum chucks, fixtures, and jigs, where the material can shine in non-load bearing applications with a need for dimensional control and machinability.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Predicting High Energy Arcing Fault Zones of Influence for Aluminum Using an Arc Flash Modeling Approach: Evaluation of a model bias, uncertainty, parameter sensitivity and zone of influence estimation

This report documents the development of an arc flash hazard model to calculate the incident energy and zone of influence from high energy arcing faults involving aluminum. The NRC has identified the potential for (HEAFs) involving aluminum to increase the damage zone beyond what is currently postulated in fire probabilistic risk assessment (PRA) methodologies. To estimate the hazard from HEAFs involving aluminum an arc flash model was developed. Differences between the initial model and nuclear power plant (NPP) fire PRA scenarios were identified. Modification of the initial model established from existing literature and test data was used to minimize these differences. The developed model was evaluated against NRC datasets to understand the model prediction and relative uncertainties. Finally, a range of fire PRA zone of influences (ZOI) were developed based on the developed model, target fragility estimates and update HEAF PRA methodology. The results were developed to support an NRC LIC-504 evaluation in tandem with other modeling efforts. The report documents the effort and provides a reference for any future advancements in arc flash modeling.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Improved Fundamental Understanding of Aluminum Chemistry and Interactions of Aluminate Anion with Co-Anions: ORNL Project Progress Report

The U.S. Department of Energy (DOE)’s Hanford Site in Washington State houses 177 underground storage tanks containing millions of gallons of nuclear and chemical waste with high aluminum content. Aluminum (Al) salt reactions with strong bases produce aluminum hydroxides, like boehmite (γ-AlOOH), which are main components of insoluble nuclear waste sludge. Understanding the morphology, crystallinity, and dissolution behavior of boehmite under waste tank conditions is necessary for improving waste management and mitigation strategies. The ORNL team uses in situ multimodal analysis strategy to study Al chemistry of simulated tank waste using microfluidic reactors and advanced chemical imaging and mass spectrometry (MS) techniques. Because the SALVI device is vacuum compatible and transferrable among different platforms, we can use it in scanning electron microscopy (SEM), vacuum ultraviolet single photon mass spectrometry (VUV SPI-MS), and time-of-flight secondary ion mass spectrometry (ToF-SIMS) to study the chemical speciation and colloid stability in liquids in this project. Additionally, ex situ transmission electron microscopy (TEM) and x-ray diffraction (XRD) spectroscopy can be used to verify particle phase to further the understanding of the Al-bearing phases. This report gives a summary of the technical progress of the ORNL tasks. A plan for year 2 performance is recommended in the summary.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Monte Carlo Study of Imaging Plate Response to Laser-Driven Aluminum Ion Beams

We measured the response of BAS-TR imaging plate (IP) to energetic aluminum ions up to 222 MeV, and compared it with predictions from a Monte Carlo simulation code using two different IP response models. Energetic aluminum ions were produced with an intense laser pulse, and the response was evaluated from cross-calibration between CR-39 track detector and IP energy spectrometer. For the first time, we obtained the response function of the BAS-TR IP for aluminum ions with a kinetic energy as high as 222 MeV. On close examination of the two IP response models, we confirm that the exponential model fits our experimental data better. Moreover, we find that the IP sensitivity in the exponential model is nearly constant in this energy range, suggesting that the response function can be determined even with little experimental data.

Won, Junho↗
NASA NTRS1966

Aluminum core structures brazed without use of flux

Aluminum alloy face sheets are brazed to aluminum alloy honeycomb cores without using corrosive flux by means of one or three methods. The completed brazed structure has the high-strength characteristics of heat treated aluminum alloys.

Source record↗
NASA NTRS1972

Diffusion of chromium and aluminum in Ni-20Cr and TDNiCr /Ni-20Cr-2ThO2/.

Diffusion coefficients have been measured for Cr51 in fine- and coarse-grained TDNiCr (Ni-20Cr-2ThO2) and in fine-grained Ni-20Cr in the temperature range from 1038 to 1200 C. Selective diffusivities have also been determined for specimens of these alloys which were aluminized to give an initial surface concentration of 5.8 wt % Al. Finally, diffusion coefficients for interdiffusion of aluminum in TDNiCr and Ni-20Cr have been obtained from electron probe microanalysis of the aluminized specimens. For a given grain size and temperature there is no difference in diffusivities for chromium diffusion in TDNiCr or Ni-20Cr. Diffusion coefficients increase with decreasing grain size for both alloys. Comparison of aluminum diffusion data obtained from electron microprobe profiles with radiotracer chromium diffusivities suggests that aluminum diffuses approximately three times faster than chromium in TDNiCr and Ni-20Cr.

Seltzer, M. S.↗
NASA NTRS1972

Boron-aluminum structural component for Shuttle.

A boron-aluminum structural component, representative of Space Shuttle fuselage structure, has been fabricated and tested as part of a program to demonstrate boron-aluminum feasibility for Shuttle applications. The 4- by 5-foot component consists of eleven 24-ply Z section stringers and a +45 degree 8-ply skin. It was tested at room temperature and at 500 F under combined compressive and shear loadings. The components for this program were fabricated in order to encounter and solve scale-up problems, and to obtain test data representative of production hardware. The data from this program are expected to allow more accurate prediction of weights and costs of boron-aluminum structures for the Space Shuttle.

Brown, E. P.↗
NASA NTRS1973

Evaluation of laminated aluminum plate for shuttle applications

Flaw growth behavior in roll diffusion bonded and adhesive bonded 2219-T87 aluminum alloy was compared to that in monolothic 2219-T87. Based on tests at 40 KSI cyclic stress, for equivalent cyclic life, a .004 interlayer laminate can tolerate a surface flaw twice as wide as in monolithic material, or provide an 8% weight saving by operating at higher stress for the same initial flaw. Roll diffusion bonded material with three structural plies of 2219-T87 and two interlayers of 1100 aluminum was prepared with interlayer thicknesses of .004, .007 and .010 in. Total laminate thickness was .130 in. The .004 interlayer laminate was most effective and gave better results than monolithic material at 40 and 48 ksi. Adhesive bonded specimens were fabricated of three sheets of 2219-T87 aluminum alloy bonded with METLBOND 329 adhesive. Adhesive bonded specimens gave longer lives to failure than diffusion bonded specimens at 40 ksi the diffusion bonded material was superior. Flaws initiated in one ply of the laminate grew to the edges of the specimen in that ply but did not propagate into adjacent plies.

Martin, M. J.↗
NASA NTRS1973

Scanning electron microscope study of polytetrafluoroethylene sliding on aluminum single crystals

Friction experiments were conducted in air with polytetrafluoroethylene (PTFE) sliding on aluminum single crystals. Mechanical scoring of the crystals with (110) and (100) orientations was observed with a single pass of the PTFE slider. No scoring was observed on the (111). The degree of scoring of the crystals is related to the hardness, with the hardest surface (111) showing no damage and the softest surface (110) showing the most severe scoring. Scoring is caused by work-hardened pieces of aluminum which, as a consequence of the adhesion between PTFE and aluminum, were pulled out of the bulk and became embedded in the PTFE polymer.

Brainard, W. A.↗
NASA NTRS1973

Effects of diffusion on aluminum depletion and degradation of NiAl coatings

Experiments were performed to critically demonstrate the effects of diffusion on the aluminum depletion and degradation of NiAl coatings on superalloys. Pack aluminized IN 100 and Mar-M200 were diffusion annealed in 0.0005 torr vacuum at 1100 C for 300 hours. Aluminum losses due to oxidation and vaporization were minimal. Metallographic and electron microprobe analyses showed considerable interdiffusion of the coating with the substrate, which caused a large decrease in the original aluminum level of the coating. Subsequent cyclic furnace oxidation tests were performed at 1100 C using 1 hour cycles on pre-diffused and as-coated specimens. The pre-diffusion treatment decreased the oxidation protection for both alloys, but more dramatically for IN 100. Identical oxidation tests of bulk NiAl, where such diffusion effects are precluded, showed no signs of degradation at twice the time needed to degrade the coated superalloys.

Smialek, J. L.↗
NASA NTRS1974

An experimental investigation of the damping contribution of an elastomeric ablator on aluminum beams

Damping results are presented for an elastometric ablation material bonded to an aluminum alloy substrate. Tests were conducted on aluminum beams 0.159, 0.318, and 0.476 cm thick, and with and without an ablator. Ablation-material thickness varied from 0.159 to 0.953 cm. Comparative damping data were obtained by using variations of the free-free beam technique with strain gages and piezoelectric transducers. Of the two test arrangements employed, the technique using strain gages produced results that indicated less restraint of the beams. Ablation material, in thicknesses less than 1 cm, substantially increased the damping parameter of the aluminum beams.

Howell, W. E.↗
NASA NTRS1974

Influence of degree of ambient medium rarefaction on deformation of copper and aluminum

The influence of high vacuum 1 x 10 to the minus 9th power torr on the plastic deformation of copper and aluminum was studied. When stretching polycrystalline aluminum and copper specimens in vacuum, it was found that the deformation at failure increases and the ultimate strength decreases. Deformation in vacuum is accompanied by the evolution of hydrogen. For copper, gas evolution is observed only at failure, while for aluminum hydrogen evolution takes place in the initial stage and the gas evolution peaks correspond to small steps on the deformation curve.

Lyubarskiy, I. M.↗
NASA NTRS1973

Increase in transmittance of unbacked aluminum filters exposed to RF or dc discharges in oxygen

Results of an experimental study of the effect of discharges in oxygen on the oxide thickness and transmittance of aluminum filters. The studies were performed by exposing the filters to RF discharges and dc glow discharges in oxygen. In all experiments except one in which an aluminum ring was used as the cathode an increase in the transmittance of the filters is noted. It is thus demonstrated that the transmittance of aluminum filters increases on exposure to electrical discharges in oxygen, although it is not certain whether this phenomenon is caused by atomic oxygen.

Hunter, W. R.↗
NASA NTRS1974

Mechanical properties of eutectic bonded boron aluminum

Results are presented of extensive testing recently completed on boron-aluminum composites to determine mechanical property data for structural design and analysis. Average property data and associated test methods are given for unidirectional and cross plied laminates at room temperature and 600 F. Results from crippling tests of hat-shaped stringers and mechanical fastener joint tests of laminates containing titanium interleaves are also presented. Compared to aluminum which has approximately same density, tests show that boron-aluminum loaded in compression is 4 1/2 times stronger and 3 1/2 times stiffer. When loaded in tension it is 2 times stronger and 3 times stiffer.

Bohlmann, R. E.↗
NASA NTRS1974

Effects of diffusion on aluminum depletion and degradation of NiAl coatings

Experiments were performed to critically demonstrate the effects of diffusion on the aluminum depletion and degradation of NiAl coatings on superalloys. Pack aluminized IN 100 and Mar-M200 were diffusion annealed in 5 mtorr vacuum at 1100 C for 300 hr. Aluminum losses due to oxidation and vaporization were minimal. Metallographic and electron microprobe analyses showed considerable interdiffusion of the coating with the substrate, which caused a large decrease in the original aluminum level of the coating. Subsequent cyclic furnace oxidation tests were performed at 1100 C using 1 hr cycles on prediffused and as-coated specimens. The prediffusion treatment decreased the oxidation and as-coated specimens. The prediffusion treatment decreased the oxidation protection for both alloys, but more dramatically for IN 100. Identical oxidation tests of bulk NiAl, where such diffusion effects are precluded, showed no signs of degradation at twice the time needed to degrade the coated superalloys.

Smialek, J. L.↗
NASA NTRS1975

Carbide coated fibers in graphite-aluminum composites

The study of protective-coupling layers of refractory metal carbides on the graphite fibers prior to their incorporation into composites is presented. Such layers should be directly wettable by liquid aluminum and should act as diffusion barriers to prevent the formation of aluminum carbide. Chemical vapor deposition was used to uniformly deposit thin, smooth, continuous coats of ZrC on the carbon fibers of tows derived from both rayon and polyacrylonitrile. A wet chemical coating of the fibers, followed by high-temperature treatment, was used, and showed promise as an alternative coating method. Experiments were performed to demonstrate the ability of aluminum alloys to wet carbide surfaces. Titanium carbide, zirconium carbide and carbide-coated graphite surfaces were successfully wetted. Results indicate that initial attempts to wet surfaces of ZrC-coated carbon fibers appear successful.

Imprescia, R. J.↗
NASA NTRS1975

The effect of thermal exposure on the mechanical properties of aluminum-graphite composites

The mechanical properties of aluminum-graphite composites were measured at room temperature in the as-received condition, after elevated temperature exposure and after thermal cycling. The composites were fabricated by solid-state diffusion bonding of liquid-phase Al-infiltrated Thornel 50 fibers. The results showed that the maximum longitudinal tensile strength of the as-received material was 80,000 psi, which corresponds well with the rule of mixture value. The composite strength was observed to vary widely, depending on the extent of wetting of the fibers by the aluminum. The strength of the composites in the transverse direction was generally very low, due to poor interfacial bonding. Aluminum carbide (Al4C3) formed at the surface of the fibers at temperatures greater than 500 C. Development of the carbide was shown to be diffusion-controlled and was dependent on the time and temperature used. It was shown that the tensile strength was virtually unaffected by heat-treatment up to 500 C; beyond that temperature a drastic degradation of tensile strength occurred. Thermal cycling of the composites below 500 C resulted in an observable degradation of the composite strength.

Khan, I. H.↗