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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

NASA's activities in the conservation of strategic aerospace materials

The primary objective of the Conservation of Strategic Aerospace Materials (COSAM) Program is to help reduce the dependence of the United States aerospace industry on strategic metals by providing the materials technology needed to minimize the strategic metal content of critical aerospace components with prime emphasis on components for gas turbine engines. Initial emphasis was placed in the area of strategic element substinction. Specifically, the role of cobalt in nickel base and cobalt base superalloys vital to the aerospace industry is being examined in great detail by means of cooperative university-industry-government research efforts. Investigations are underway in the area of "new classes" of alloys. Specifically, a study was undertaken to investigate the mechanical and physical properties of intermetallics that contain a minimum of the strategic metals. Current plans for the much larger COSAM Program are also presented.

Stephens, J. R.↗
NASA NTRS1981

Conservation of Strategic Aerospace Materials (COSAM)

Research efforts to reduce the dependence of the aerospace industry on strategic metals, such as cobalt (Co), columbium (Cb), tantalum (Ta), and chromium (Cr), by providing the materials technology needed to minimize the strategic metal content of critical aerospace components for gas turbine engines are addressed. Thrusts in three technology areas are identified: near term activities in the area of strategic element substitution; intermediate-range activities in the area of materials processing; and long term, high risk activities in the area of 'new classes' of high temprature metallic materials. Specifically, the role of cobalt in nickel-base and cobalt-base superalloys vital to the aerospace industry is examined along with the mechanical and physical properties of intermetallics that will contain a minimum of the stragetic metals.

Stephens, J. R.↗
NASA NTRS1980

NASA's activities in the conservation of strategic aerospace materials

The United States imports 50-100 percent of certain metals critical to the aerospace industry, namely, cobalt, columbium, chromium, and tantalum. In an effort to reduce this dependence on foreign sources, NASA is planning a program called Conservation of Strategic Aerospace Materials (COSAM), which will provide technology minimizing strategic metal content in the components of aerospace structures such as aircraft engines. With a proposed starting date of October 1981, the program will consist of strategic element substitution, process technology development, and alternate materials research. NASA's two-fold pre-COSAM studies center on, first, substitution research involving nickel-base and cobalt-base superalloys (Waspaloy, Udimet-700, MAE-M247, Rene 150, HA-188) used in turbine disks, low-pressure blades, turbine blades, and combustors; and, second, alternate materials research devoted initially to investigating possible structural applications of the intermetallic alloys nickel aluminide and iron aluminide.

Stephens, J. R.↗
NASA NTRS1981

Hybrid A/D converter for 200 deg C operation

A 12 bit A/D converter was designed and developed which will operate at 200 C with .05 linearity, 1/accuracy, 350 WSec conversion time, and only 455 mW power consumption. This product also necessitated the development of a unique three metal system in which aluminum wire bonding is done utilizing aluminum bonding pads, gold wire bonding to all gold areas, and employment of a nickel interface between gold and aluminum connections. This system totally eliminates the formation of a intermetallics at the bonding interface which can lead to bond failure. This product represents an advancement in electronics as it proved the operation of integrated circuits at high temperature, as well as providing information about both the electrical and mechanical reliability of hybrid circuits at 200 C.

Sullivan, M. R.↗
NASA NTRS1981

Hard permanent magnet development trends and their application to A.C. machines

The physical and magnetic properties of Mn-Al-C, Fe-Cr-Co, and RE-TM (rare earth-transition metal intermetallics) in polymer and soft metal bonded or sintered form are considered for ac circuit machine usage. The manufacturing processes for the magnetic materials are reviewed, and the mechanical and electrical properties of the magnetic materials are compared, with consideration given to the reference Alnico magnet. The Mn-Al-C magnets have the same magnetic properties and costs as Alnico units, operate well at low temperatures, but have poor high temperature performance. Fe-Cr-Co magnets also have comparable cost to Alnico magnets, and operate at high or low temperature, but are brittle, expensive, and contain Co. RE-Co magnets possess a high energy density, operate well in a wide temperature range, and are expensive. Recommendation for exploring the rare-earth alternatives are offered.

Mildrum, H. F.↗
NASA NTRS1982

COSAM program overview

The COSAM program for reduction of the use of strategic alloying elements in nickel-based superalloys for gas turbine engines was reviewed. Sources, consumption, and pricing of cobalt, tantalum, columbium, and chromium are surveyed. Research projects in strategic element substitution, advanced processing concepts, and the development of alternate materials (intermetallics and iron-base alloys) are listed and research plans for FY 1983 and FY 1984 summarized.

Stephens, J. R.↗
NASA NTRS1982

High temperature deformation of NiAl and CoAl

The high temperature mechanical properties of the aluminides are reviewed with respect to their potential as high temperature structural materials. It is shown that NiAl and CoAl are substantially stronger than the pure metals Ni and Co at high temperatures and approach the strength of some superalloys, particularly when those superalloys are tested in "weak" directions. The factors that limit and control the high temperature strengths of NiAl and CoAl are examined to provide a basis for the development of intermetallic alloys of this type.

Nix, W. D.↗
NASA NTRS1983

Influence of thermomechanical processing on elevated temperature slow plastic flow properties of B2 aluminide Fe-39.8at.% Al

A study of the elevated temperature slow plastic flow properties of the B2 aluminide Fe-39.8at.% Al was undertaken. Polycrystalline materials possessing several different microstructures were produced by the hot extrusion of prealloyed powder and, in some cases, postextrusion heat treatments. Compression tests were conducted in air at 1200, 1300 and 1400 K. Such testing revealed that the extrusion temperature affected the active deformation mechanisms where material extruded at 1505 K had a stress exponent about twice that of the intermetallic extruded at 1200 K. Grain size refinement to about 10 microns was found to strengthen the Fe-39.8at.% Al material; unfortunately, the effectiveness of such strengthening is limited to a homologous temperature of about 0.75 for strain rates of commercial interest (less than 10 to the -7th/sec).

Whittenberger, J. D.↗
NASA NTRS1984

A simple application of the Bailey-Orowan creep model to Fe-39.8 at. pct Al and gamma/gamma prime - alpha

The results of a study to determine the recovery rates and work-hardening coefficients for creep from constant cross-head speed compressive tests are presented. Stressing and straining rates are computed from measured time-load curves obtained from compression testing between 1200 and 1400 K of several B2 crystal structure Fe-39.8 Al intermetallic materials and the directionally solidified eutectic alloy gamma/gamma prime alpha. These quantities are then fitted to the universal form of the Bailey-Orowan equation for creep. The recovery rates were found to be functions of nominal strain rate, stress, and temperature, while the hardening coefficients were dependent only on temperature. While the work-hardening coefficient for gamma/gamma prime - alpha was about 0.05 of the elastic modulus, the work-hardening coefficients for Fe-39.8 at. pct Al were less than 0.002 of the modulus.

Whittenberger, J. D.↗
NASA NTRS1984

High temperature properties of equiatomic FeAl with ternary additions

The aluminide intermetallic compounds are considered potential structural materials for aerospace applications. The B2 binary aluminide FeAl has a melting point in excess of 1500 K, is of simple cubic structure, exits over a wide range of composition with solubility for third elements and is potentially self-protecting in extreme environments. The B2 FeAl compound has been alloyed with 1 to 5 at % ternary additions of Si, Ti, Zr, Hf, Cr, Ni, Co, Nb, Ta, Mo, W, and Re. The alloys were prepared by blending a third elemental powder with prealloyed binary FeAl powder. Consolidation was by hot extrusion at 1250 K. Annealing studies on the extruded rods showed that the third element addition can be classified into three categories based upon the amount of homogenization and the extent of solid solutioning. Constant strain rate compression tests were performed to determine the flow stress as a function of temperature and composition. The mechanical strength behavior was dependent upon the third element homogenization classification.

Titran, R. H.↗
NASA NTRS1984

The B2 aluminides as alternative materials

The potential of the B2 aluminides as structural material alternatives for the strategic element containing superalloys currently used in gas turbine engines is being explored with emphasis on the equiatomic Fe and Ni aluminides. Although Co is a strategic material, the equiatomic Co aluminide is also being studied to gain a more complete understanding of these fourth period intermetallics. Research focuses on initial processing techniques such as ingot melting, power metallurgy, and rapid solidification with and without additional thermomechanical processing; high temperature deformation - primarily compressive creep; compositional effects within the binary B2 aluminides; third-element alloying addition effects on high temperature strength and oxidation resistance, and near room temperature ductility as influenced by processing, alloying, and grain size. Various programs now underway are reviewed and some highlights of research results are presented.

Stephens, J. R.↗
NASA NTRS1984

Rapidly solidified NiAl and FeAl

Melt spinning was used to produce rapidly solidified ribbons of the B2 intermetallics NiAl and FeAl. Both Fe-40Al and Fe-45Al possessed some bend ductility in the as spun condition. The bend ductility of Fe-40Al, Fe-45Al, and equiatomic NiAl increased with subsequent heat treatment. Heat treatment at approximately 0.85 T (sub m) resulted in significant grain growth in equiatomic FeAl and in all the NiAl compositions. Low bend ductility in both FeAl and NiAl generally coincided with intergranular failure, while increased bend ductility was characterized by increasing amounts of transgranular cleavage fracture.

Gaydosh, D. J.↗
NASA NTRS1985

Oxidizing seal for a turbine tip gas path

The sealing of the gas path in a gas turbine engine at the blade tips is improved by maintaining a minimum clearance between the rotor blade tips and the gas path seal. This is accomplished by taking advantage of an increase in volume during controlled oxidation of certain intermetallic compounds which have high melting points. The increase in volume closes the clearance subsequent to a rub between the blades and the seal. Thus, these compounds re-form the tip seal surface to assure continued engine efficiency.

Cawley, J. D.↗
NASA NTRS1985

Oxidation resistant slurry coating for carbon-based materials

An oxidation resistant coating is produced on carbon-base materials, and the same processing step effects an infiltration of the substrate with silicon containing material. The process comprises making a slurry of nickel and silicon powders in a nitrocellulose lacquer, spraying onto the graphite or carbon-carbon substrate, and sintering in vacuum to form a fused coating that wets and covers the surface as well as penetrates into the pores of the substrate. Optimum wetting and infiltration occurs in the range of Ni-60 w/o Si to Ni-90 w/o Si with deposited thicknesses of 25-100 mg/sq. cm. Sintering temperatures of about 1200 C to about 1400 C are used, depending on the melting point of the specific coating composition. The sintered coating results in Ni-Si intermetallic phases and SiC, both of which are highly oxidation resistant.

Smialek, J. L.↗
NASA NTRS1985

Study of the Reactive-element Effect in Oxidation of Fe-cr Alloys Using Transverse Section Analytical Electron Microscopy

The role of trace additions of reactive elements like Y, Ce, Th, or Hf to Cr bearing alloys was studied by applying a new developed technique of transverse section analytical electron microscopy. This reactive-element effect improves the high temperature oxidation resistance of alloys by strongly reducing the high temperature oxidation rate and enhancing the adhesion of the oxide scale, however, the mechanisms for this important effect remain largely unknown. It is indicated that the presence of yttrium affects the oxidation of Fe-Cr-Y alloys in at least two ways. The reactive element alters the growth mechanism of the oxide scale as evidenced by the marked influence of the reactive element on the oxide scale microstructure. The present results also suggest that reactive-element intermetallic compounds, which internally oxidize in the metal during oxidation, act as sinks for excess vacancies thus inhibiting vacancy condensation at the scale-metal interface and possibly enhancing scale adhesion.

King, W. E.↗
NASA NTRS1986

Undercooled and rapidly quenched Ni-Mo alloys

Hypoeutectic, eutectic, and hypereutectic nickel-molybdenum alloys were rapidly solidified by both bulk undercooling and melt spinning techniques. Alloys were undercooled in both electromagnetic levitation and differential thermal analysis equipment. The rate of recalescence depended upon the degree of initial undercooling and the nature (faceted or nonfaceted) of the primary nucleating phase. Alloy melts were observed to undercool more in the presence of primary Beta (NiMo intermetallic) phase than in gamma (fcc solid solution) phase. Melt spinning resulted in an extension of molybdenum solid solubility in gamma nickel, from 28 to 37.5 at % Mo. Although the microstructures observed by undercooling and melt spinning were similar the microsegregation pattern across the gamma dendries was different. The range of microstructures evolved was analyzed in terms of the nature of the primary phase to nucleate, its subsequent dendritic growth, coarsening and fragmentation, and final solidification of interfenderitic liquid.

Tewari, S. N.↗
NASA NTRS1986

High temperature dispersion strengthening of NiAl

A potential high temperature strengthening mechanism for alloys based on the intermetallic compound NiAl was investigated. This study forms part of an overall program at NASA Lewis Research Center for exploring the potential of alloys based on NiAl for high temperature applications. An alloy containing 2.26 at% Nb and produced by hot extrusion of blended powders was examined in detail using optical and electron microscopy. Interdiffusion between the blended Nb and NiAl powders results in the formation of intermediate phases. A fine dispersion of precipitates of a hexagonal, ordered NiAlNb phases in a matrix of NiAl can be produced and this results in strengthening of the alloy by interfering with dislocation motion at high temperature. These precipitates are, however, found to coarsen during the high temperature (1300 K) deformation at slow strain rates and this may impose some limitatioins on the use of this strengthening mechanism.

Sherman, M.↗
NASA NTRS1985

Microstructure and fracture in SiC whisker reinforced 2124 aluminum composite

The microstructures of extruded and hot-rolled 2124 Al-15 percent (by weight) SiC whisker composites have been investigated, experimentally. Among the specific factors studied were: the strength of the whisker-matrix interfaces; (2) the presence of oxides; (3) the presence of defective whiskers; (4) and the presence of distribution of intermetallic compounds, impurities in the SiC(w) powder, and microstructural inhomogeneities. Modifications in the microstructure of the SiC/AL composites due to hot rolling and extrusion are illustrated in a series of microphotographs. It was found that hot rolling along the axis of extrusion was associated with some types of whisker damage, while the whiskers still retain their original orientation. Hot-rolling perpendicular to the axis of extrusion, however, tended to rotate the whiskers and produced a nearly isotropic material. Whisker free zones were virtually eliminated or reduced in size by hot rolling. In situ Auger fractography of the composite showed that the interfacial bonding between the SiC and the Al matrix was good and that Al2O2 had no significant influence on the fracture mechanics of the composite.

Nieh, T. G.↗