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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

A life study of ausforged, standard forged, and standard machined AISI M-50 spur gears

Tests were conducted at 350 K with three groups of 8.9 cm pitch diameter spur gears made of vacuum-induction melted (VIM), vacuum-arc remelted (VAR), AISI M-50 steel and one group of vacuum-arc remelted (VAR) AISI 9310 steel. The pitting fatigue life of the standard forged and ausforged gears was approximately five times that of the VAR AISI 9310 gears and ten times that of the bending fatigue life of the standard machined VIM-VAR AISI M-50 gears run under identical conditions. There was a slight decrease in the 10-percent life of the ausforged gears from that for the standard forged gears. However, the difference is not statistically significant. The standard machined gears failed primarily by gear tooth fracture while the forged and ausforged VIM-VAR AISI M-50 and the VAR AISI 9310 gears failed primarily by surface pitting fatigue. The ausforged gears had a slightly greater tendency to fail by tooth fracture than the standard forged gears.

Townsend, D. P.↗
NASA NTRS1975

The effect of forging history on the strength and microstructure of TDNiCr /Ni-20Cr-2ThO2/

Forging variables were evaluated to determine their influence on the elevated temperature strength and microstructure of TDNiCr. Grain size was the principal microstructural feature related to elevated temperature strength and was controlled primarily by the thermomechanical variables of forging temperature and final annealing condition. Tests at 1366 K revealed a factor of eight increase in tensile strength as grain size increased from 1 to 150 microns, while stress-rupture strength improved by three to five times as grain size increased from 15 to 150 microns. Forged material of grain size greater than or equal to about 150 microns displayed a level of elevated temperature strength comparable to that of optimized TDNiCr sheet. The presence of a preponderance of small twins and a strong preferred orientation may have also been factors contributing to the excellent high temperature strength of large grain forged material.

Filippi, A. M.↗
NASA NTRS1986

Surface fatigue and failure characteristics of hot forged powder metal AISI 4620, AISI 4640, and machined AISI 4340 steel spur gears

Spur gear surface fatigue endurance tests were conducted to investigate hot forged powder metal AISI 4620 and 4640 steel for use as a gear material, to determine endurance characteristics and to compare the results with machined AISI 4340 and 9310 steel gear materials. The as-forged and unground SISI 4620 gear exhibited a 10 percent fatigue life that was approximately one-fourth of that for AISI 9310 and less than one-half that for the AISI 4340 gears. The forged and finish ground AISI 4620 gears exhibited a 10 percent life, approximately 70 percent that of AISI 9310 and slightly better than that of AISI 4340. The AISI 4640 hot forged gears had less fracture toughness and slightly less fatigue life than the AISI 4620 test gears.

Townsend, D. P.↗
NASA NTRS1987

Surface fatigue and failure characteristics of hot-forged powder metal AISI 4620, AISI 4640, and machined AISI 4340 steel spur gears

Spur gear surface fatigue endurance tests were conducted to investigate hot forged powder metal AISI 4620 and 4640 steel for use as a gear material, to determine endurance characteristics and to compare the results with machined AISI 4340 and 9310 steel gear materials. The as-forged and unground AISI 4620 gear exhibited a 10 percent fatigue life that was approximately one-fourth of that for AISI 9310 and less than one-half that for the AISI 4340 gears. The forged and finish ground AISI 4620 gears exhibited a 10 percent life, approximately 70 percent that of AISI 9310 and slightly better than that of AISI 4340. The AISI 4640 hot forged gears had less fracture toughness and slightly less fatigue life than the AISI 4620 test gears.

Townsend, Dennis P.↗
DOE OSTI2025

Effect of cold forging on the microstructure and corrosion behavior of type 316L stainless steel in molten FLiNaK salt

Here, the effect of cold forging on the microstructure and corrosion behavior of 316L stainless steel (SS) in molten salt was investigated. Static corrosion experiments were performed in FLiNaK (LiF-NaF-KF: 46.5–11.5–42 mol.%) at 600 °C for 50 h in a glove box. The results show that cold forging gives rise to enhanced corrosion of 316L SS in molten fluoride salt due to the increase of crystallographic defects. Based on the potentiodynamic polarization results, the corrosion current density of 50 % cold-forged 316L SS is about 2.1 times larger than that of the as-received 316L SS in molten FLiNaK salt at 600 °C.

316L stainless steel↗
DOE OSTI2024

Utah FORGE 2-2439v2: Characterizing In-Situ Stress with Laboratory Modelling and Field Measurements - 2024 Annual Workshop Presentation

This is a presentation on A Multi-Component Approach to Characterizing In-Situ Stress at the Utah FORGE Site: Laboratory Modelling and Field Measurements project by The University of Pittsburgh, presented by Andrew Bunger. The project characterizes the stress in the Utah FORGE EGS reservoir using three methods: Method 1: Demonstrate complimentary laboratory rock-core stress estimation combined with Machine Learning approach for measuring in-situ stress from field sonic log data; Method 2: Complete field based in-situ measurement (mini-frac); and Method 3: Develop a mechanics-based method for connection near wellbore stress measurements to stresses away from the well-bore. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 14, 2024.

15 GEOTHERMAL ENERGY↗
NASA NTRS1978

Characterization of large 2219 aluminum alloy hand forgings for the space shuttle solid rocket booster

The mechanical properties, including fracture toughness, and stress corrosion properties of four types of 2219-T852 aluminum alloy hand forgings are presented. Weight of the forgings varied between 450 and 3500 lb at the time of heat treatment and dimensions exceeded the maximum covered in existing specifications. The forgings were destructively tested to develop reliable mechanical property data to replace estimates employed in the design of the Space Shuttle Solid Rocket Booster (SRB) and to establish minimum guaranteed properties for structural refinement and for entry into specification revisions. The report summarizes data required from the forgers and from the SRB Structures contractor.

Brennecke, M. W.↗
NASA NTRS2001

High Temperature, Slow Strain Rate Forging of Advanced Disk Alloy ME3

The advanced disk alloy ME3 was designed in the HSR/EPM disk program to have extended durability at 1150 to 1250 F in large disks. This was achieved by designing a disk alloy and process producing balanced monotonic, cyclic, and time-dependent mechanical properties. combined with robust processing and manufacturing characteristics. The resulting baseline alloy, processing, and supersolvus heat treatment produces a uniform, relatively fine mean grain size of about ASTM 7, with as-large-as (ALA) grain size of about ASTM 3. There is a long term need for disks with higher rim temperature capabilities than 1250 F. This would allow higher compressor exit (T3) temperatures and allow the full utilization of advanced combustor and airfoil concepts under development. Several approaches are being studied that modify the processing and chemistry of ME3, to possibly improve high temperature properties. Promising approaches would be applied to subscale material, for screening the resulting mechanical properties at these high temperatures. n obvious path traditionally employed to improve the high temperature and time-dependent capabilities of disk alloys is to coarsen the grain size. A coarser grain size than ASTM 7 could potentially be achieved by varying the forging conditions and supersolvus heat treatment. The objective of this study was to perform forging and heat treatment experiments ("thermomechanical processing experiments") on small compression test specimens of the baseline ME3 composition, to identify a viable forging process allowing significantly coarser grain size targeted at ASTM 3-5, than that of the baseline, ASTM 7.

Gabb, Timothy P.↗
NASA NTRS2004

Assessment of NASA Dual Microstructure Heat Treatment Method for Multiple Forging Batch Heat Treatment

NASA dual microstructure heat treatment technology previously demonstrated on single forging heat treat batches of a generic disk shape was successfully demonstrated on a multiple disk batch of a production shape component. A group of four Rolls-Royce Corporation 3rd Stage AE2100 forgings produced from alloy ME209 were successfully dual microstructure heat treated as a single heat treat batch. The forgings responded uniformly as evidenced by part-to-part consistent thermocouple recordings and resultant macrostructures, and from ultrasonic examination. Multiple disk DMHT processing offers a low cost alternative to other published dual microstructure processing techniques.

Gayda, John↗
DOE OSTI2024

Utah FORGE Project 3-2417: DAS Microseismic Event Catalog from the 16A/16B Circulation Test, 2023

This preliminary data archive includes the relocated microseismic event catalog, 1D velocity model, and methods report from DAS acquisition conducted during the Well 16A and 16B circulation test (July 19th and 20th, 2023) at Utah FORGE. The methods report describes all processing steps, including real-time event detection, hierarchical clustering, joint velocity/hypocenter inversion, and relocation. The resulting work is accepted and will be presented at IMAGE 2024. This dataset was acquired by the FOGMORE R&D project (Fiber Optic MOnitoring for Reservoir Evolution), Utah FORGE R&D Project 3-2417.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE 3-2514: Strain Sensing Array for Deformation Characterization - 2024 Annual Workshop Presentation

This is a presentation on the Strain Sensing Array to characterize deformation at the FORGE site project by Clemson University, presented by Lawrence Murdoch. The project's objective was to evaluate the feasibility of measuring and interpreting tensor strain data to improve the performance of EGS. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 23, 2024.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE Project 3-2417: Meteorological Data During 2023 Completion/Circulation

This preliminary data archive includes meteorological data recorded at the Utah FORGE facility over the period of time including the completion/cementing of well 78-16B and the initial 2023 circulation test, largely occurring in June/July/August of 2023. This information may prove useful for understanding seismic and other instrumentation responses during these activities. The meteorological station was installed June 23rd, 2023 during drilling; the circulation test occurred in mid July of 2023 (July 4-19). The included files span this period. All sensors were installed at the 16 pad and hence reflect weather state at the site. This dataset was acquired by the FOGMORE R&D project (Fiber Optic MOnitoring for Reservoir Evolution), Utah FORGE R&D Project 3-2417.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE: Geochemical Data for Cold Groundwaters and Produced Geothermal Fluids

Geochemical data for cold groundwaters and produced geothermal fluids around the Utah FORGE site. The data is compiled into four tables in the attached Excel File. Table 1 is a compilation of compositions (anions, cations, weak acids, oxygen, hydrogen, and carbon isotopes) for cold groundwaters and produced geothermal waters in the Milford valley, Utah. Table 2 is a compilation of noble gas (He, Ne, Ar) and He and Ne isotopic compositions for cold groundwaters and produced geothermal waters in the Milford valley, Utah. Table 3 provides values for calculated advective and diffusive fluxes of helium. Table 4 provides values of calculated subsurface stored heat between the Opal Mound fault and the Utah FORGE site, which are related to volumes of recently solidified magmatic heat sources.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE 2-2404: Application of Advanced Techniques for Determination of Reservoir-Scale Stress State - 2024 Annual Workshop Presentation

This is a presentation on the Application of Advanced Techniques for Determination of Reservoir-Scale Stress State at FORGE by the University of Oklahoma, presented by Ahmad Ghassemi. This video discusses how magnitude and orientation of natural in-situ principal stresses at depth is necessary for effective and economical geothermal reservoir development including drilling, stimulation, and reservoir management. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 13, 2024.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE 5-2615: Determination and Analysis of Thermo-poromechanical Response of Fractured Rock - 2024 Annual Workshop Presentation

This is a presentation on the Determination and Modeling-Informed Analysis of Thermo-poromechanical Response of Fractured Rock for Application to FORGE by the University of Oklahoma, presented by Ahmad Ghassemi. This video presentation discusses how to improve understanding and control of coupled thermoporomechanical (or thermo-hydro-mechanical-THM) processes in reservoir development, and to demonstrate its role in interpretations of the fracture closure pressure. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 13-15, 2024.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Utah FORGE: 2024 Discrete Fracture Network Model Data

The Utah FORGE 2024 Discrete Fracture Network (DFN) Model dataset provides a set of files representing discrete fracture network modeling for the FORGE site near Milford, Utah. The dataset includes four distinct DFN model file sets, each corresponding to different time frames and modeling approaches in 2024. These models characterize both natural and induced fractures in the geothermal reservoir, which consists of crystalline granitic and metamorphic rock approximately 8,000 feet below the ground surface. The dataset includes a reference DFN model from February 2024 that incorporates planar fractures and well trajectories, as well as upscaled permeability, porosity, compressibility, and storage values on specified grids. Additionally, there are models based on new microseismic (MEQ) data from May and July 2024, including fracture planes fitted to the latest MEQ catalog datasets, tensile fractures from hydraulic stimulation, and an alternative connected DFN for modeling purposes. Coordinate data is provided in both global and local frames, with detailed instructions on the transformations used to align with principal stress orientations. The dataset also includes notes and calculation files for estimating fracture sizes and differences between various fracture sets. There are subfolders for Global Coordinates and Local Coordinates. To move from the global to the local coordinate frame, fractures and wells were a) rotated 20 degrees counterclockwise looking down about the global point (335376.400482041, 4263189.99998761, 250.093546450195) to better align with the principal stresses; and b) translated by (-335408.68, -4263010.9, 1150). Upscaled permeability values using the _XYZ suffix show directions with respect to the global XYZ coordinate frame, while those using the _IJK suffix are aligned with local coordinate frame.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Utah FORGE: LBNL Reports on VEMP Electromagnetic Data Collection and Processing - 2024

This archive contains reports related to Vertical Electromagnetic Profiling (VEMP) tool data collection and processing at Utah FORGE in 2024. The first report describes LBNL's effort to collect electromagnetic geophysical data with the tool in well 78-32B and a downhole electrode in well 16A. The second report describes the final data acquisition and processing of the VEMP electromagnetic data collected at the Utah FORGE site in May of 2024. Also included are a noise analysis as well as a comparison of the data to numerical models. This was originally presented as a paper at the 2025 Stanford Geothermal Workshop.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

FORGE STRESS annual report

The project's goal is to combine high-fidelity numerical models and true-triaxial block fracturing tests at high temperatures to understand the relationship between in situ stress, thermal effects, wellbore orientations and hydraulic fracture patterns. The numerical models are calibrated against field data, such as well pressures and microseismic data, and employed to estimate the in situ stress at the FORGE site. Laboratory experiments investigate the complex physics driving hydraulic fracture nucleation in EGS, enhancing understanding of the role of parameters like temperature, well orientation, and stress. Additionally, they are employed to validate some of the numerical tools used in the project. The project will have a significant impact by: (1) improving the characterization of the in-situ stress field at FORGE; (2) demonstrating the use of high-fidelity modeling tools for EGS; (3) providing a unique set of high-temperature hydraulic fracturing results to identify key components for in-situ stress estimation, validate current theories, and propose new ones; (4) offering a validated set of numerical tools within an open-source simulation framework, GEOS, that will be available to any future user.

15 GEOTHERMAL ENERGY↗