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Reversible reactions between hydrogen and such materials as iron/titanium and magnesium/ nickel alloy may provide a means for storing hydrogen fuel. A demonstration model of an iron/titanium hydride storage bed is described. Hydrogen from the hydride storage bed powers a converted gasoline electric generator.
Conversion electron Mossbauer spectroscopy (CEMS) of samples from the Santa Catharina iron meteorite shows the presence of the ordered iron-nickel phase with 50% Ni, tetrataenite, and of the paramagnetic iron-nickel phase with 25% Ni. The FeNi phase with 50% Ni amounts to 70% of the iron-nickel alloys. Futhermore, the CEM spectra show the presence of small peaks from one or more spinel compounds. These small peaks are more pronounced when regions near the rim of the samples are analyzed. The X-ray diffraction of different areas of the samples, both optically dark and optically light areas, shows the presence of a diffraction pattern from a single f.c.c. lattice with a lattice parameter of a=3.58A This means that the two different Fe-Ni phases seen in the CEMS analysis occupy the same lattice. The X-ray photographs also show the presence of super-structure reflections from the ordered FeNi phase, and that the orientation of the f.c.c. lattice is the same within the whole sample.
A description of an experimental facility used to determine the ignition and combustion characteristics of metallic materials is given. The results obtained for aluminum 6061, 302 stainless steel, and the nickel alloy - N06625 are presented.
Two separate projects were carried out to study alloys whose solidification structures can be strongly influenced by the presence of a container during melting and solidifications. One project involved containerless solidification of hypermonotectic Au35Rh65 alloys. This alloy exhibits liquid immiscibility over a temperature range. It has been suggested that containerless melting might be one solution to the problem of sedimentation in the dispersions of immiscible liquid phases. However, surface tension driven flows could also lead to accumulation of the minority liquid phase at the external surface of a containerlessly melted alloy. The research underway is a first step in determining the influence of containerless, microgravity processing on immiscible alloys. Nickel-niobium alloys were studied using the drop tube facility. One alloy in this system, a Ni60Nb40 alloy, is a good candidate for the formation of a bulk metallic glass. Amorphous alloys of this composition were produced using thin film and mechanical alloying techniques. However, theory indicates that if heterogeneous nucleation can be avoided, it should be possible to produce an amorphous structure in this system using a moderate cooling rate from the melt. The containerless melting and solidification capabilities of the drop tube faciltiy provide ideal conditions for a study of this type. To date, several Ni60Nb40 samples have been levitated, melted and cooled during 4.6 seconds of free fall in the 100 meter drop tube. Structures obtained are discussed.
Simple punching tool used to make holes in thin metal sheets, without burrs and edge deformations. Tool used on such materials as stainless steel, nickel alloys, beryllium, copper, and aluminum, in thicknesses of 0.002 to 0.010 in. With new punch, hole size held to tolerance of 0.025 mm. Includes rubber punch extruding into hole in top plate, pushing out exposed portion of clamped metal sheet.
Effects of galvanic coupling between graphite/epoxy composite material, G/E, and D6AC steel, 6061-T6 aluminum, and Inconel(R) 718 nickel alloy in salt water described in report. Introductory section summarizes previous corrosion studies of G/E with other alloys. Details of sample preparation presented along with photographs of samples before and after immersion.
Permanent repairs made without welding. Technique used to repair nickel-alloy nozzle jacket of Space Shuttle main engine. Applicable to other metal heat-exchanger jackets with similar configurations. Does not require welding, brazing, soldering, or other operations involving high temperatures and consequent damage to surrounding areas. Portion of jacket around damaged area removed by grinding and polishing out to edges adjacent to tube/jacket braze bonds. Spaces between tubes filled with wax preventing contamination of spaces during subsequent plating.
Hypersonic vehicles are envisioned to require, in addition to carbon-carbon and ceramic-matrix composities for leading edges heated to above 2000 F, such 600 to 1800 F operating temperature materials as advanced Ti alloys, nickel aluminides, and metal-matrix composited; These possess the necessary low density and high strength and stiffness. The primary design drivers are maximum vehicle heating rate, total heat load, flight envelope, propulsion system type, mission life requirements and liquid hydrogen containment systems. Attention is presently given to aspects of these materials and structures requiring more intensive development.
A 'bread pan' capsule has been designed which allows large numbers of tensile specimens to be simultaneously exposed to molten LiOH, its vapor, and vacuum. Capsules and specimens fabricated from the pure nickel alloy Ni-200 were annealed for 401 hours and 2500 hours at 775 K. Examination of the exposed materials revealed that little outward damage in terms of visible attack, weight change, or loss of room temperature tensile properties occurred. In particular, the mechanical behavior of hydroxide-contaminated alloy was essentially identical to that receiving a simple thermal exposure in vacuum. Examination of the microstructures revealed that LiOH did produce some nonuniform, shallow intergranular corrosion in NI-200; however, the extent of the damage was insufficient to produce weakening or embrittlement.
The solubility of hydrogen, at a fixed hydrogen pressure, was measured in two different heat treatment conditions in both IN-100 and Waspaloy by equilibrium and analysis. The diffusion coefficients were determined by measuring the rate of hydrogen evolution in a vacuum. Hydrogen evolution appeared to be a diffusion-controlled process in all cases. For hydrogen diffusion in Waspaloy, Delta H was 38.5 kJ and D0 was 2.6 x 10 to the -7th sq/s. For IN-100, Delta H was 68.2 kJ and D0 was 59 x 10 to the -7th sq/s. The values for Waspaloy are close to those for pure nickel. The values for IN-100 are more similar to high nickel alloys that show trapping or surface layer impedance.
A thermoviscoplastic finite element method employing the Bodner-Partom constitutive model is used to investigate the response of simplified thermal-structural models to intense local heating. With rapid rises of temperature, the nickel alloy structures display initially higher yield stresses due to strain rate effects. As temperatures approach elevated values, yield stress and stiffness degrade rapidly and pronounced plastic deformation occurs.
Porous, ropelike barrier prevents recirculating flow of hot, hydrogen-rich steam from reaching nickel-alloy bellows seal located deep in gap in wall of combustion chamber. Proven successful protecting bellows seal at different values of protrusion of coolant tubes giving rise to recirculating hot flow. Similar barriers help block deleterious recirculating flow of hot gases in other combustion chambers such as furnaces and turbomachines.
Vacuum plasma spraying used to fabricate large parts with complicated contours and inner structures, without uninspectable welds. Reduces time, and expense of fabrication. Wall of combustion chamber built up inside of outer nickel-alloy jacket by plasma spraying. Particles of metal sprayed partially melted in plasma gun and thrown at supersonic speed toward deposition surface. Vacuum plasma-spray produces stronger bond between the grooves and covering layer completing channels and wall of combustion chamber. In tests, bond withstood pressure of 20 kpsi, three times allowable limit by old method.
The history of computational structural analysis is reviewed and anticipated requirements for the design, development, and support of advanced commercial engines is discussed. The present commercial engine environment is comprised primarily of turbofan engines containing monolithic titanium and nickel alloys. Future commercial engines will make extensive use of composite materials to meet demanding high temperature requirement and aggressive weight goals, since only modestly higher capabilities can be anticipated in monolithic materials. Engine configurations will include ducted and/or unducted propfans and super turbojet in addition to turbofans.
This report describes the design of an experiment for evaluating monolithic and composite material specimens in a high-temperature environment and subject to big thermal gradients. The material specimens will be exposed to aerothermal loads that correspond to thermally similar engine operating conditions. Materials evaluated in this study were monolithic nickel alloys and silicon carbide. In addition, composites such as tungsten/copper were evaluated. A facility to provide the test environment has been assembled in the Engine Research Building at the Lewis Research Center. The test section of the facility will permit both regular and Schlieren photography, thermal imaging, and laser Doppler anemometry. The test environment will be products of hydrogen-air combustion at temperatures from about 1200 F to as high as 4000 F. The test chamber pressure will vary up to 60 psia, and the free-stream flow velocity can reach Mach 0.9. The data collected will be used to validate thermal and stress analysis models of the specimen. This process of modeling, testing, and validation is expected to yield enhancements to existing analysis tools and techniques.
The solid to liquid phase transformation of LiOH at 744.3 K is considered to be an ideal candidate thermal energy storage (TES) mechanism for a Rankine heat engine based solar dynamic system operating at approximately 682 K. While pure nickel is thought to be a suitable containment material for LiOH, long term containment is of concern because molten hydroxides are usually corrosive. Two commercially pure nickel alloys, Ni-200 and Ni-201, were exposed to molten LiOH, its vapor, and vacuum at 775 K for periods ranging from 50 to 5000 h, and simple mechanical property measurements (77 to 900 K tensile and 750 K creep rupture) of exposed alloys were undertaken. The mechanical property test procedures are described and tabular lists of the test data are presented.
As predicted by friction theory, experiments showed that friction and surface damage of metals can be reduced by solid surface films. The ability of materials to form surface films that prevent welding was a very important factor in wear of dry and boundary lubricated surfaces. Films of graphitic carbon on cast irons, nio on nickel alloys, and feo and fe sub 3 o sub 4 on ferrous materials were found to be beneficial. Abrasive films such as fe sub 2 o sub 3 or moo sub 3 were definitely detrimental. It appears that the importance of oxide films to friction and wear processes has not been fully appreciated.
A thermoviscoplastic finite element method employing the Bodner-Partom constitutve model is used to investigate the response of simplified thermal-structural models to intense local heating. The computational method formulates the problem in rate and advances the solution in time by numerical integration. The thermoviscoplastic response of simplified structures with prescribed temperatures is investigated. With rapid rises of temperature, the nickel alloy structures display initially higher yield stresses due to strain rate effects. As temperatures approach elevated values, yield stress and stiffness degrade rapidly and pronounced plastic deformation occurs.