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NASA NTRS2019

Mechanical Tensile Testing of Hiperco 50A at Cryogenic Temperature

Hiperco 50A is a highly desired material for use in cryogenic applications, specifically for adiabatic demagnetization refrigerators (ADRs) due to its magnetic field shielding capabilities. Although the alloy has good strength, there is a concern with the material's brittle behavior which is believed to worsen at low temperature based on previous tests. The testing described here investigates the mechanical properties of Hiperco 50A at cryogenic temperature through mechanical tensile testing to failure and evaluation of the failed coupons. The methods and techniques used to determine the elongation, yield strength, ultimate tensile strength, and break strength of the material as well as the results will be presented here.

material properties↗
NASA NTRS1992

Relative sliding durability of candidate high temperature fiber seal materials

The relative sliding durability behavior of six candidate ceramic fibers for high temperature sliding seal applications is reviewed and compared. Pin on disk tests were used to evaluate potential seal materials by sliding a tow or bundle of the candidate ceramic fiber against a superalloy test disk. Tests were conducted in air under a 2.65 N load, at a sliding velocity of 0.025 m/sec and at temperatures from 25 to 900 C. Friction was measured during the tests and fiber wear, indicated by the extent of fibers broken in the tow or bundle, was measured at the end of each test. For most of the fibers, friction and wear increase with test temperature. The relative fiber durability ranking correlates with tensile strength, indicating that tensile data, which is more readily available than sliding durability data, may be useful in predicting fiber wear behavior under various conditions. A dimensional analysis of the wear data shows that the fiber durability is related to a dimensionless durability ratio which represents the ratio of the fiber strength to the fiber stresses imposed by sliding. The analysis is applicable to fibers with similar diameters and elastic moduli. Based upon the results of the research program, three fiber candidates are recommended for further study as potential seal materials. They are a silicon based complex carbide-oxide fiber, an alumina-boria-silica and an aluminosilicate fiber.

Dellacorte, Christopher↗
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 NTRS1982

Mechanical properties of low tantalum alloys

The mechanical property behavior of equiaxed cast B-1900 + Hf alloy as a function of tantalum content was studied. Tensile and stress rupture characterization was conducted on cast to size test bars containing tantalum at the 4.3% (standard level), 2.2% and 0% levels. Casting parameters were selected to duplicate conditions used to prepare test specimens for master metal heat qualification. The mechanical property results as well as results of microstructural/phase analysis of failed test bars are presented.

Kortovich, C. S.↗
NASA NTRS1985

Mechanical behavior of 18 Ni 200 grade maraging steel at cryogenic temperatures

A comprehensive study was conducted to characterize the mechanical behavior of 18 Ni 200 grade maraging steel for cryogenic applications in the National Transonic Facility. Tensile, fatigue, impact, and fracture toughness properties were determined at room and cryogenic temperatures. Experimental variables included product form, specimen orientation, and variation in metallurgical condition accomplished with a grain refining heat treatment. Room temperature tensile yield strength was approximately 200 ksi, while the yield strength at -275 F was approximately 260 ksi. Charpy V-notch energy absorption values and fracture toughness values of 18 Ni steel were found to be dependent on temperature, product form, orientation, and metallurgical condition. Fracture toughness values ranged from 80 to 113 ksi-sq rt in. at room temperature and from 67 to 90 ksi-sq rt in. at -275 F. The results of this study indicate that 18 Ni 200 grade maraging steel exceeds the strength criterion of 150 ksi minimum yield strength for use in cryogenic wind tunnel models but is marginal with respect to the 85 ksi sq rt in fracture toughness criterion at -275 F.

Wagner, J. A.↗
NASA NTRS1990

Matrix density effects on the mechanical properties of SiC/RBSN composites

The room temperature mechanical properties were measured for SiC fiber reinforced reaction-bonded silicon nitride composites (SiC/RBSN) of different densities. The composites consisted of approx. 30 vol percent uniaxially aligned 142 micron diameter SiC fibers (Textron SCS-6) in a reaction-bonded Si3N4 matrix. The composite density was varied by changing the consolidation pressure during RBSN processing and by hot isostatically pressing the SiC/RBSN composites. Results indicate that as the consolidation pressure was increased from 27 to 138 MPa, the average pore size of the nitrided composites decreased from 0.04 to 0.02 microns and the composite density increased from 2.07 to 2.45 gm/cc. Nonetheless, these improvements resulted in only small increases in the first matrix cracking stress, primary elastic modulus, and ultimate tensile strength values of the composites. In contrast, HIP consolidation of SiC/RBSN resulted in a fully dense material whose first matrix cracking stress and elastic modulus were approx. 15 and 50 percent higher, respectively, and ultimate tensile strength values were approx. 40 percent lower than those for unHIPed SiC/RBSN composites. The modulus behavior for all specimens can be explained by simple rule-of-mixture theory. Also, the loss in ultimate strength for the HIPed composites appears to be related to a degradation in fiber strength at the HIP temperature. However, the density effect on matrix fracture strength was much less than would be expected based on typical monolithic Si3N4 behavior, suggesting that composite theory is indeed operating. Possible practical implications of these observations are discussed.

Bhatt, Ramakrishna T.↗
NASA NTRS1990

Matrix density effects on the mechanical properties of SiC fiber-reinforced silicon nitride matrix properties

The room temperature mechanical properties were measured for SiC fiber reinforced reaction-bonded silicon nitride composites (SiC/RBSN) of different densities. The composites consisted of approx. 30 vol percent uniaxially aligned 142 micron diameter SiC fibers (Textron SCS-6) in a reaction-bonded Si3N4 matrix. The composite density was varied by changing the consolidation pressure during RBSN processing and by hot isostatically pressing the SiC/RBSN composites. Results indicate that as the consolidation pressure was increased from 27 to 138 MPa, the average pore size of the nitrided composites decreased from 0.04 to 0.02 microns and the composite density increased from 2.07 to 2.45 gm/cc. Nonetheless, these improvements resulted in only small increases in the first matrix cracking stress, primary elastic modulus, and ultimate tensile strength values of the composites. In contrast, HIP consolidation of SiC/RBSN resulted in a fully dense material whose first matrix cracking stress and elastic modulus were approx. 15 and 50 percent higher, respectively, and ultimate tensile strength values were approx. 40 percent lower than those for unHIPed SiC/RBSN composites. The modulus behavior for all specimens can be explained by simple rule-of-mixture theory. Also, the loss in ultimate strength for the HIPed composites appears to be related to a degradation in fiber strength at the HIP temperature. However, the density effect on matrix fracture strength was much less than would be expected based on typical monolithic Si3N4 behavior, suggesting that composite theory is indeed operating. Possible practical implications of these observations are discussed.

Bhatt, Ramakrishna T.↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗
NASA NTRS1991

In-situ x-ray monitoring of damage accumulation in SiC/RBSN tensile specimens

The room-temperature tensile testing of silicon carbide fiber reinforced reaction-bonded silicon nitride (SiC/RBSN) composite specimens was monitored by using in-situ x ray film radiography. Radiographic evaluation before, during, and after loading provided data on the effect of preexisting volume flaws (high density impurities, and local density variations) on the fracture behavior of composites. Results from (0)1, (0)3, (0)5, and (0)8 composite specimens, showed that x ray film radiography can monitor damage accumulations during tensile loading. Matrix cracking, fiber-matrix debonding, and fiber pullout were imaged throughout the tensile loading history of the specimens. Further, in-situ film radiography was found to be a helpful and practical technique for estimating interfacial shear strength between the SiC fiber and the RBSN matrix by the matrix crack spacing method. It is concluded that pretest, in-situ, and post-test radiography can provide for a greater understanding of ceramic matrix composite mechanical behavior, a verification of related experimental procedures, and a validation and development of related analytical models.

Baaklini, George Y.↗
NASA NTRS1977

Experimental evaluation of the tensor polynomial criterion for designing composite structures

A comprehensive experimental and analytical evaluation of the tensor polynomial failure criterion was undertaken to determine its capability for predicting the ultimate strength of a composite limina subject to a plane stress state. Results are presented demonstrating that a quadratic formulation is too conservative and a cubic representation is required. Strength comparisons with test data derived from glass/epoxy and graphite/epoxy tubular specimens are also provided to validate the cubic strength criterion. Environmental effects including ambient temperature, exposure to vacuum, length of post-cure time, and rate of cool down were also investigated. Behavior changes associated with polymer (epoxy) matrix composites were determined in terms of variations in stiffness and tensile strength.

Tennyson, R. C.↗
NASA NTRS1986

Physical aging in epoxy matrices and composites

Postcured specimens of Thornell 300 carbon-fiber/Fiberite 934 epoxy as well as Fiberite 934 epoxy resin were quenched from above the glass transition temperature and annealed at 140, 110, or 80 C for times up to 100,000 min. No weight gain or loss was observed during annealing at these temperatures, but significant time-dependent variations were observed in density, modulus, hardness, damping, moisture absorption ability, and thermal expansion characteristics. The relations between the excess thermodynamic properties of epoxy glasses and their time-dependent behavior are discussed. The discussion is illustrated by results obtained by differential scanning calorimetry, dynamic mechanical analysis, tensile testing, solid state nuclear magnetic resonance spectroscopy, and small-angle X-ray scattering.

Kong, Eric Siu-Wai↗
NASA NTRS1989

Fatigue crack growth in a unidirectional SCS-6/Ti-15-3 composite

An investigation was conducted to characterize and model the fatigue crack growth (FCG) behavior of a SCS-6/Ti-15-3 metal matrix composite. Part of the study was conducted using a fatigue loading stage mounted inside a scanning electron microscope (SEM). This unique facility allowed high magnification viewing of the composite fatigue processes and measurement of the near crack tip displacements. The unidirectional composite was tested in the (0)8 (i.e., longitudinal) and (90)8 (i.e., transverse) orientations. For comparison purposes unreinforced matrix material produced by the identical process as the reinforced material was also tested. The results of the study reveal that the fatigue crack growth behavior of the composite is a function of specimen geometry, fiber orientation and the interaction of local stress fields with the highly anisotropic composite. In the case of (0)8 oriented single edge notch (SEN) specimens and (90)8 oriented compact tension (CT) specimens, the crack growth was normal to the loading direction. However, for the (0)8 CT specimens the crack grew mostly parallel to the loading and the fiber direction. The unusual fatigue behavior of the (0)8 CT specimens was attributed to the specimen geometry and the associated high tensile bending stresses perpendicular to the fiber direction. These stresses resulted in preferential cracking in the weak interface region perpendicular to the fiber direction. The interface region, and in particular the carbon coating surrounding the fiber proved to be the composites weakest link. In the (0)8 SEN the crack growth was confined to the matrix leaving behind unbroken fibers which bridged the cracked surfaces. As the crack grew longer, more fibers bridged the crack resulting in a progressive decrease in the crack growth rates and eventual crack arrest. The actual near crack tip displacement measurements were used in a proposed formulation for a bridging-corrected effective crack driving force, delta K(sub eff). This parameter was able to account for most of the experienced bridging and correlated the (0)8 SEN fatigue crack growth data reasonably well.

Kantzos, Peter↗
NASA NTRS1989

Failure modes and damage accumulation in laminated composites with free edges

The influence of fiber orientation, stacking sequence, material properties and edge effects on the accumulation of damage and modes of failure in angle-ply and quasi-isotropic composite laminates are studied. Experimental results are presented for graphite-epoxy and graphite-polyimide coupons subjected to tensile load. It is shown that all the parameters studied can have a significant influence on the behavior of the composite.

Herakovich, Carl T.↗
NASA NTRS1991

Fatigue crack growth in a unidirectional SCS-6/Ti-15-3 composite

An investigation was conducted to characterize and model the fatigue crack growth (FCG) behavior of an SCS-6/Ti-15-3 metal matrix composite. Part of the study was conducted using a fatigue loading stage mounted inside a scanning electron microscope (SEM). The results of the study reveal that the fatigue crack growth behavior of the composite is a function of specimen geometry, fiber orientation, and interaction of local stress fields with the highly anisotropic composite. In the case of (0)8 oriented single edge notch specimens and (90)8 oriented compact tension (CT) specimens, the crack growth was normal to the loading direction. However, for the (0)8 CT specimens, the crack grew mostly parallel to the loading and the fiber direction. The unusual fatigue behavior of the (0)8 CT specimens is attributed to the specimen geometry and the associated high tensile bending stresses perpendicular to the fiber direction.

Kantzos, Peter↗
NASA NTRS2014

Electron Beam Freeform Fabrication of Titanium Alloy Gradient Structures

Historically, the structural optimization of aerospace components has been done through geometric methods. A monolithic material is chosen based on the best compromise between the competing design limiting criteria. Then the structure is geometrically optimized to give the best overall performance using the single material chosen. Functionally graded materials offer the potential to further improve structural efficiency by allowing the material composition and/or microstructural features to spatially vary within a single structure. Thus, local properties could be tailored to the local design limiting criteria. Additive manufacturing techniques enable the fabrication of such graded materials and structures. This paper presents the results of a graded material study using two titanium alloys processed using electron beam freeform fabrication, an additive manufacturing process. The results show that the two alloys uniformly mix at various ratios and the resultant static tensile properties of the mixed alloys behave according to rule-of-mixtures. Additionally, the crack growth behavior across an abrupt change from one alloy to the other shows no discontinuity and the crack smoothly transitions from one crack growth regime into another.

Brice, Craig A.↗
NASA NTRS1991

In situ X-ray monitoring of damage accumulation in SiC/RBSN tensile specimens

The room-temperature tensile testing of silicon carbide fiber reinforced reaction-bonded silicon nitride (SiC/RBSN) composite specimens was monitored by using in-situ X-ray film radiography. Radiographic evaluation before, during, and after loading provided data on the effect of preexisting volume flaws (high density impurities, and local density variations) on the fracture behavior of composites. Results from (O)1, (O)3, (O)5, and (O)8 composite specimens showed that X-ray film radiography can monitor damage accumulations during tensile loading. Matrix cracking, fiber-matrix debonding, and fiber pullout were imaged throughout the tensile loading history of the specimens. Further, in-situ film radiography was found to be a helpful and practical technique for estimating interfacial shear strength between the SiC fiber and the RBSN matrix by the matrix crack spacing method. It is concluded that pretest, in-situ, and post-test radiography can provide for a greater understanding of ceramic matrix composite mechanical behavior, a verification of related experimental procedures, and a validation and development of related analytical models.

Baaklini, George Y.↗
NASA NTRS1989

Oxidation effects on the mechanical properties of SiC fiber-reinforced reaction-bonded silicon nitride matrix composites

The room temperature mechanical properties of SiC fiber reinforced reaction bonded silicon nitride composites were measured after 100 hrs exposure at temperatures to 1400 C in nitrogen and oxygen environments. The composites consisted of approx. 30 vol percent uniaxially aligned 142 micron diameter SiC fibers in a reaction bonded Si3N4 matrix. The results indicate that composites heat treated in a nitrogen environment at temperatures to 1400 C showed deformation and fracture behavior equivalent to that of the as-fabricated composites. Also, the composites heat treated in an oxidizing environment beyond 400 C yielded significantly lower tensile strength values. Specifically in the temperature range from 600 to 1000 C, composites retained approx. 40 percent of their as-fabricated strength, and those heat treated in the temperatures from 1200 to 1400 C retained 70 percent. Nonetheless, for all oxygen heat treatment conditions, composite specimens displayed strain capability beyond the matrix fracture stress; a typical behavior of a tough composite.

Bhatt, Ramakrishna T.↗
NASA NTRS1992

Oxidation effects on the mechanical properties of a SiC-fiber-reinforced reaction-bonded Si3N4 matrix composite

The room-temperature mechanical properties of SiC fiber reinforced reaction bonded silicon nitride composites were measured after 100 hrs exposure at temperatures to 1400 C in nitrogen and oxygen environments. The composites consisted of approx. 30 vol percent uniaxially aligned 142 micron diameter SiC fibers in a reaction bonded Si3N4 matrix. The results indicate that composites heat treated in a nitrogen environment at temperatures to 1400 C showed deformation and fracture behavior equivalent to that of the as-fabricated composites. Also, the composites heat treated in an oxidizing environment beyond 400 C yielded significantly lower tensile strength values. Specifically in the temperature range from 600 to 1000 C, composites retained approx. 40 percent of their as-fabricated strength, and those heat treated in the temperatures from 1200 to 1400 C retained 70 percent. Nonetheless, for all oxygen heat treatment conditions, composite specimens displayed strain capability beyond the matrix fracture stress; a typical behavior of a tough composite.

Bhatt, Ramakrishna T.↗