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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 NTRSDate not supplied

Effects of Alloying Elements on Twinning in Ni-Based Superalloys

Micro-twinning is the major creep deformation mechanism in Ni-based superalloys at temperatures above 700 °C. Recent experiments suggest that superlattice stacking faults in y' phase may serve as the precursors to twin formation. Segregation of alloying elements to these precursors may have a significant effect on formation and extension of micro-twins. Using atomistic modeling we investigate and explain the effects of Nb and Cr alloying additions on these processes. The simulation shows that Nb increases the creep resistance which is mostly associated with impeding the reordering of the high energy double complex stacking fault. Cr, on the other hand, promotes twin growth, degrading the high temperature creep properties. These results can help to understand the effects of elemental composition of the alloy on creep resistance.

Ni-based superalloys↗
NASA NTRS1981

Study of the effects of gaseous environmental on the hot corrosion of superalloy materials

Studies have been conducted to examine the effect of low concentrations of NaCl(g) on the high temperature oxidation behavior of complex superalloys and potential coating formulations modified by silicon and reactive element (i.e., yttrium and hafnium) additions. Depending on alloy composition, a variety of effects were thermogravimetrically produced. Aluminum free alloys such as MAR-M509 and Hastelloy X with molybdenum and tungsten in solid solution showed accelerated (or breakaway) kinetics similar to that observed for Ni-Cr alloys. For IN-792, an alloy high in chromium and low in aluminum, molybdenum and tungsten present in solid solution does not adversely affect oxidation kinetics in the presence of NaCl(g). On the other hand, nickel-base alloys high in aluminum and molybdenum are catastrophically attacked by NaCl-bearing atmospheres. Silicon additions were, in general, observed to slightly improve the oxidation resistance of Ni, Ni-40Cr and CoCrAlY compositions in NaCl(g)-bearing atmospheres. To the degree that processes responsible for Al2O3 whisker formation deleteriously affect protective scale adherence, the addition of yttrium or hafnium can inhibit such whisker growth.

Smeggil, J. G.↗
NASA NTRS1997

Design for Oxidation Resistance

Alloys intended for use in high-temperature environment rely on the formation of a continuous, compact, slow-growing oxide layer for oxidation and hot corrosion resistance. To be protective, this oxide layer must be chemically, thermodynamically stable. Successful alloy design for oxidative environment is best achieved by developing alloys that are capable of forming adherent scales of either alumina (Al2O3), chromia (Cr2O3), or silica (SiO2). In this article, emphasis has been placed on the issue related to high-temperature oxidation of superalloys used in gas turbine engine application. Despite the complexity of these alloys, optimal performance has been associated with protective alumina scale formation. As will be described below, both compositional makeup and protective coatings play key role in providing oxidation protection. Other high-temperature materials described include nickel and titanium aluminide intermetallics, refractory metal, and ceramics.

Smialek, James L.↗
NASA NTRS1973

Alloy composition effects on oxidation products of VIA, B-1900, 713C, and 738X: A high temperature diffractometer study

High temperature X-ray diffraction studies were performed to investigate isothermal and cyclic oxidation at 1000 and 1100 C of the nickel-base superalloys VIA, B-1900, 713C, and 738X. Oxidation was complex. The major oxides, Al2O3, Cr2O3, and the spinels, formed in amounts consistent with alloy chemistry. The alloys VIA and B-1900 (high Al, low Cr alloys) tended to form Al2O3 and NiAl2O4; 738X (high Cr, low Al) formed Cr2O3 and NiCr2O4. A NiTa2O6 type of oxide formed in amounts approximately proportional to the refractory metal content of the alloy. One of the effects of cycling was to increase the amount of spinels formed.

Garlick, R. G.↗
NASA NTRS1973

Examination of oxide scales in the SEM using backscattered electron images

The complementary use of the scanning electron microscope in the backscattered electron mode with the more usual secondary electron mode results in a significant increase in the versatility of the instrument, since regions of different chemical composition can be readily detected, and their morphology examined. The use of this technique to examine complex oxide scales formed on heat-resistant alloys is described, and in particular the location of thoria particles in the scale formed on a Ni-20 wt pct Cr-2.3 wt pct ThO2 alloy, and the examination of the behavior of yttrium during the high-temperature oxidation of a Co-Cr-Al-Y alloy are discussed.

Price, C. W.↗
NASA NTRS2003

Heats of Segregation of BCC Metals Using Ab Initio and Quantum Approximate Methods

Many multicomponent alloys exhibit surface segregation, in which the composition at or near a surface may be substantially different from that of the bulk. A number of phenomenological explanations for this tendency have been suggested, involving, among other things, differences among the components' surface energies, molar volumes, and heats of solution. From a theoretical standpoint, the complexity of the problem has precluded a simple, unified explanation, thus preventing the development of computational tools that would enable the identification of the driving mechanisms for segregation. In that context, we investigate the problem of surface segregation in a variety of bcc metal alloys by computing dilute-limit heats of segregation using both the quantum-approximate energy method of Bozzolo, Ferrante and Smith (BFS), and all-electron density functional theory. In addition, the composition dependence of the heats of segregation is investigated using a BFS-based Monte Carlo procedure, and, for selected cases of interest, density functional calculations. Results are discussed in the context of a simple picture that describes segregation behavior as the result of a competition between size mismatch and alloying effects

Good, Brian↗
NASA NTRS1974

Fabrication of tungsten wire reinforced nickel-base alloy composites

Fabrication methods for tungsten fiber reinforced nickel-base superalloy composites were investigated. Three matrix alloys in pre-alloyed powder or rolled sheet form were evaluated in terms of fabricability into composite monotape and multi-ply forms. The utility of monotapes for fabricating more complex shapes was demonstrated. Preliminary 1093C (2000F) stress rupture tests indicated that efficient utilization of fiber strength was achieved in composites fabricated by diffusion bonding processes. The fabrication of thermal fatigue specimens is also described.

Brentnall, W. D.↗
NASA NTRS1978

Trends in aerospace structures

Recent developments indicate that there may soon be a revolution in aerospace structures. Increases in allowable operational stress levels, utilization of high-strength, high-toughness materials, and new structural concepts will highlight this advancement. Improved titanium and aluminum alloys and high-modulus, high-strength advanced composites, with higher specific properties than aluminum and high-strength nickel alloys, are expected to be the principal materials. Significant advances in computer technology will cause major changes in the preliminary design cycle and permit solutions of otherwise too-complex interactive structural problems and thus the development of vehicles and components of higher performance. The energy crisis will have an impact on material costs and choices and will spur the development of more weight-efficient structures. There will also be significant spinoffs of aerospace structures technology, particularly in composites and design/analysis software.

Card, M. F.↗
NASA NTRS1995

Micromechanics of composites with shape memory alloy fibers in uniform thermal fields

Analytical procedures are developed for a composite system consisting of shape memory alloy fibers within an elastic matrix subject to uniform temperature fluctuations. Micromechanics for the calculation of the equivalent properties of the composite are presented by extending the multi-cell model to incorporate shape memory alloy fibers. A three phase concentric cylinder model is developed for the analysis of local stresses which includes the fiber, the matrix, and the surrounding homogenized composite. The solution addresses the complexities induced by the nonlinear dependence of the in-situ martensite fraction of the fibers to the local stresses and temperature, and the local stresses developed from interactions between the fibers and matrix during the martensitic and reverse phase transformations. Results are presented for a nitinol/epoxy composite. The applications illustrate the response of the composite in isothermal longitudinal loading and unloading, and in temperature induced actuation. The local stresses developed in the composite under various stages of the martensitic and reverse phase transformation are also shown.

Birman, Victor↗
NASA NTRS1985

Differential-Coil Eddy-Current Material Sorter

Small metal or other electrically conductive parts of same shape but different composition quickly sorted with differential-coil eddy-current sorter. Developed to distinguish between turbine blades of different alloys, hardnesses, and residual stress, sorter generally applicable to parts of simple and complex shape.

Nummelin, J.↗
NASA NTRS2006

Effect of Composite Substrates on the Mechanical Behavior of Brazed Joints in Metal-Composite System

Advanced composite components are being considered for a wide variety of demanding applications in aerospace, space exploration, and ground based systems. A number of these applications require robust integration technologies to join dissimilar materials (metalcomposites) into complex structural components. In this study, three types of composites (C-C, C-SiC, and SiC-SiC) were vacuum brazed to commercially pure Ti using the active metal braze alloy Cusil-ABA (63Ag-35.3Cu-1.75Ti). Composite substrates with as fabricated and polished surfaces were used for brazing. The microstructure and composition of the joint, examined using scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS), showed sound metallurgical bonding in all systems. The butt strap tensile (BST) test was performed on bonded specimens at room and elevated temperatures. Effect of substrate composition, interlaminar properties, and surface roughness on the mechanical properties and failure behavior of joints will be discussed.

Singh, M.↗
NASA NTRSDate not supplied

The Effect of Trailing Edge Grid Resolution in Large-Eddy Simulations

Ceramic Matrix Composite (CMC) with environmental barrier coating can tolerate significantly higher temperatures compared with the conventional metal alloy blades and thus can help achieve higher thermal efficiency in gas turbine engines. Due to the complex fabrication process of CMC blades, larger blade trailing edge thicknesses and larger leading-edge radii of curvature are expected. These features significantly alter aerodynamic performance especially near the trailing edge and thus the loss profile. In previous studies, the authors used the large eddy simulation (LES) as well as the Reynolds Averaged Navier-Stokes (RANS) coupled with an intermittency function-based transition model to simulate an aerodynamics performance of three different CMC blades and compared the predictions against the data acquired at NASA Glenn Transonic Turbine Blade Cascade Rig. Although we were able to successfully predict different characteristics of aerodynamic performance among three different blades (e.g., pressure loading and integrated losses), LES consistently predicted a small recirculation bubble at the end of the suction side. This was not inconsistent with the physics of the flow, but the pressure loading, locally, near the trailing edge, and as a result, the measured wake profiles did not match the experimental data. To delve further into these issues, a new LES grid with a much finer mesh near the trailing edge was generated where the spanwise extent of the grid was increased by 50%. An LES simulation for the CMC blade with the largest trailing edge thicknesses at the high-freestream turbulence (Tu=13%) condition showed that using such a mesh is necessary for LES to accurately capture the transition phenomena on the suction side. The resulting total pressure coefficient profile and the shift of the wake profile were greatly improved.

CMC↗
NASA NTRSDate not supplied

The Effect of Trailing Edge Grid Resolution in Large-Eddy Simulations

Ceramic Matrix Composite (CMC) with environmental barrier coating can tolerate significantly higher temperatures compared with the conventional metal alloy blades and thus can help achieve higher thermal efficiency in gas turbine engines. Due to the complex fabrication process of CMC blades, larger blade trailing edge thicknesses and larger leading-edge radii of curvature are expected. These features significantly alter aerodynamic performance especially near the trailing edge and thus the loss profile. In previous studies, the authors used the large eddy simulation (LES) as well as the Reynolds Averaged Navier-Stokes (RANS) coupled with an intermittency function-based transition model to simulate an aerodynamics performance of three different CMC blades and compared the predictions against the data acquired at NASA Glenn Transonic Turbine Blade Cascade Rig. Although we were able to successfully predict different characteristics of aerodynamic performance among three different blades (e.g., pressure loading and integrated losses), LES consistently predicted a small recirculation bubble at the end of the suction side. This was not inconsistent with the physics of the flow, but the pressure loading, locally, near the trailing edge, and as a result, the measured wake profiles did not match the experimental data. To delve further into these issues, a new LES grid with a much finer mesh near the trailing edge was generated where the spanwise extent of the grid was increased by 50%. An LES simulation for the CMC blade with the largest trailing edge thicknesses at the high-freestream turbulence (Tu=13%) condition showed that using such a mesh is necessary for LES to accurately capture the transition phenomena on the suction side. The resulting total pressure coefficient profile and the shift of the wake profile were greatly improved.

LES↗
NASA NTRS1995

Low Cost Fabrication of Silicon Carbide Based Ceramics and Fiber Reinforced Composites

A low cost processing technique called reaction forming for the fabrication of near-net and complex shaped components of silicon carbide based ceramics and composites is presented. This process consists of the production of a microporous carbon preform and subsequent infiltration with liquid silicon or silicon-refractory metal alloys. The microporous preforms are made by the pyrolysis of a polymerized resin mixture with very good control of pore volume and pore size thereby yielding materials with tailorable microstructure and composition. Mechanical properties (elastic modulus, flexural strength, and fracture toughness) of reaction-formed silicon carbide ceramics are presented. This processing approach is suitable for various kinds of reinforcements such as whiskers, particulates, fibers (tows, weaves, and filaments), and 3-D architectures. This approach has also been used to fabricate continuous silicon carbide fiber reinforced ceramic composites (CFCC's) with silicon carbide based matrices. Strong and tough composites with tailorable matrix microstructure and composition have been obtained. Microstructure and thermomechanical properties of a silicon carbide (SCS-6) fiber reinforced reaction-formed silicon carbide matrix composites are discussed.

Singh, M.↗
NASA NTRS2010

The Development of Titanium Alloys for Application in the Space Shuttle Main Engine

The high-strength-to-weight ratio of titanium alloys, particularly at cryogenic temperatures, make them attractive for application in rocket engines - offering the potential of superior performance while minimizing component weight. This was particularly attractive for rotating components, such as pump impellers, where titanium alloys presented the potential to achieve a major advance in rotational tip speed, with a reduction in stages and resultant saving in pump weight and complexity. The investigation into titanium alloys for application in cryogenic turbopumps began in the early 1960's. However, it was found that the reactivity of titanium limited applications and produced unique processing challenges. Specialized chemical compositions and processing techniques had to be developed. A substantial amount of material properties testing and trials in experimental turbopumps occurred, ultimately leading to application in the Space Shuttle Main Engine. One particular alloy stood out for use at liquid hydrogen temperatures, Ti-5Al-2.5Sn ELI. This alloy was employed for several critical components. This presentation deals with the development effort, the challenges that were encountered and operational experiences with Ti-5Al-2.5Sn ELI in the SSME.

Halchak, John A.↗
NASA NTRS2017

Cryogenic Thermal Conductivity Measurements on Candidate Materials for Space Missions

Spacecraft and instruments on space missions are built using a wide variety of carefully-chosen materials. It is common for NASA engineers to propose new candidate materials which have not been totally characterized at cryogenic temperatures. In many cases a material's cryogenic thermal conductivity must be known before selecting it for a specific space-flight application. We developed a test facility in 2004 at NASA's Goddard Space Flight Center to measure the longitudinal thermal conductivity of materials at temperatures between 4 and 300 Kelvin, and we have characterized many candidate materials since then. The measurement technique is not extremely complex, but proper care to details of the setup, data acquisition and data reduction is necessary for high precision and accuracy. We describe the thermal conductivity measurement process and present results for ten engineered materials, including alloys, polymers, composites, and a ceramic.

James Tuttle↗
NASA NTRS1984

Study of high performance alloy electroforming

Using the two nickel-manganese alloy electroforming baths of near identical compositions, panels were electroformed under the same deposition parameters of current density, bath temperature, pH, and pulse plating conditions of duty cycle and frequency. By changing the electrolyte agitation conditions, significant effects on mechanical properties were noted. Since electrolyte agitation conditions on the typical flat panels studied to date will not be identical to those existing on a complex curved shape such as the SSME combustion chamber simulation, it is most important that these effects be evaluated prior to Phase B studies. The subscale chamber has been fabricated and shield support tooling is being made. Electroforming of optimized alloy test bars is being deferred until the electrolyte agitation effects are more fully appraised.

Malone, G. A.↗
NASA NTRS1976

Hydrogen enhanced crack growth in 18 Ni maraging steels

The kinetics of sustained-load subcritical crack growth for 18 Ni maraging steels in high-purity hydrogen are examined using the crack-tip stress intensity factor K as a measure of crack driving force. Crack growth rate as a function of stress intensity exhibited a clearly defined K-independent stage (Stage II). Crack growth rates in an 18 Ni (grade 250) maraging steel are examined for temperatures from -6 to +100 C. A critical temperature was observed above which crack growth rates became diminishingly small. At lower temperatures the activation energy for Stage II crack growth was found to be 16.7 plus or minus 3.3 kJ/mole. Temperature and hydrogen partial pressure are shown to interact in a complex manner to determine the apparent Kth (stress intensity level below which no observable crack growth occurs) and the crack growth behavior. Comparison of results on '250' and '300' grades of 18 Ni maraging steel indicate a significant influence of alloy composition and/or strength level on the crack growth behavior.

Hudak, S. J., Jr.↗