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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Development of Shape Memory Alloys- Challenges and Solutions

Shape memory alloys (SMAs) are a unique class of multifunctional materials that have the ability to recover large deformations or generate high stresses in response to thermal, mechanical andor electromagnetic stimuli. These abilities have made them a viable option for actuation systems in aerospace, medical, and automotive applications, amongst others. However, despite many advantages and the fact that SMA actuators have been developed and used for many years, so far they have only found service in a limited range of applications. In order to expand their applications, further developments are needed to increase their reliability and stability and to address processing, testing and qualification needed for large-scale commercial application of SMA actuators. In this seminar, historical inhibitors of SMA applications and current research efforts by NASA Glenn Research Center and collaborators will be discussed. Relationships between fundamental physicalscientific understanding, and the direct transition to engineering and design of mechanisms using these novel materials will be highlighted. Examples will be presented related to targeted alloy development, microstructural control, and bulk-scale testing as a function of stresses, temperatures and harsh environments. The seminar will conclude with a summary of SMA applications under development and current advances.

Shape Memory Alloy↗
NASA NTRS1998

On the Cu-Nb Phase Diagram and Solidified Microstructures

Container and containerless processing was employed to determine liquidus temperatures and to examine microstructural development in the Cu-Nb system. The Cu-Nb phase diagram of an S-shaped, near-horizontal liquidus, has been confirmed by both the temperature-time profiles and resultant microstructures with only Nb dendrites in a Cu matrix, which were obtained from crucible experiments under clean conditions. However, the microstructural pathways of Cu-Nb alloys are particularly sensitive to processing variables. By the addition of oxygen impurities or rapid solidification, droplet-shaped morphology was observed for some compositions, implying occurrence of a liquid-phase separation. The effects of impurities and cooling rates are analyzed in connection with a stable and metastable liquid miscibility gap, respectively.

Li, D.↗
NASA NTRS1996

Development of Low Density Titanium Alloys for Structural Applications

In this report the results of a program designed to reduce the density of titanium by adding magnesium are presented. Because these two elements are immiscible under conventional ingot metallurgy techniques, two specialized powder metallurgy methods namely, mechanical alloying (MA) and physical vapor deposition (PVD) were implemented. The mechanical alloying experiments were done both at the University of Idaho and at the Defense Research Agency in UK. Since titanium is reactive with interstitial elements, a secondary goal of this research was to correlate solubility extensions with interstitial contamination content, especially oxygen and nitrogen. MA was carried out in SPEX 8000 shaker mils and different milling containers were utilized to control the level of contamination. Results showed that solubilities of Mg in Ti were obtained up to 28 at.% (16.4 wt. %) Mg in Ti for Ti-39.6 at. % (25 wt. %) Mg alloys, which greatly exceed those obtained under equilibrium conditions. This reflects a density reduction of approximately 26 %. Contamination of oxygen and nitrogen seemed to increase the solubility of magnesium in titanium in some cases; however, we were not able to make a clear correlation between contamination levels with solubilities. Work at the DRA has emphasized optimization of present PVD equipment, specifically composition and temperature control. Preliminary PVD data has shown Ti-Mg deposits have successfully been made up to 2 mm thick and that solubility extensions were achieved. The potential for density reduction of titanium by alloying with magnesium has been demonstrated; however, this work has only scratched the surface of the development of such low density alloys. Much research is needed before such alloys could be implemented into industry. Further funding is required in order to optimize the MA/PVD processes including contamination control, determination of optimal alloy compositions, microstructure development, and mechanical property determination.

Froes, F. H.↗
NASA NTRS2012

Correlation of Fracture Behavior With Microstructure in Friction Stir Welded, and Spin Formed AI-Li 2195 Domes

Single-piece, spin-formed domes manufactured from friction stir welded (FSW) plates of Al-Li alloy 2195 have the potential to reduce the cost of fabricating cryogenic propellant tanks. Mechanical properties in the completed domes can be related directly to the final material condition and the microstructures developed. However, these new fabrication techniques have resulted in unexpected material challenges, such as abnormal grain growth in the weld nugget and the propensity for fracture in the adjacent thermo-mechanically affected zone (TMAZ). In this study, the microstructure and texture transformations within the TMAZ are related to fracture location in the vicinity of the weldment. The texture variations in the TMAZ are caused primarily by the varying amounts of shear deformation introduced during the FSW process. Grain morphology and microtexture characteristics are examined as a function of location in the TMAZ via electron backscatter diffraction (EBSD). A strong correlation between fracture location and the presence of texture banding in the TMAZ is observed. The fracture path tends to follow a distinct region of low Taylor Factor (TF) grains.

Tayon, Wesley A.↗
NASA NTRS1977

Microstructure of hot-pressed Al2O3-Si3N4 mixtures as a function of holding temperature

Powder mixtures of 40 m/o Si3N4-60 m/o Al2O3 were hot-pressed at 4000 psi at various holding temperatures from 1100 C to 1700 C. Scanning and transmission electron microscopy results were correlated to X-ray phase analysis and density measurements. The progressively developed microstructure was used to interpret the densification behavior of SiAlON.

Yeh, H. C.↗
NASA NTRS1976

Microstructure of hot-pressed Al2O3-Si3N4 mixtures as a function of holding temperature

Powder mixtures of 40 m/o Si3N4-60 m/o Al2O3 were hot-pressed at 4000 psi at various holding temperatures from 1100 C to 1700 C. Scanning Electron Microscopy and Transmission Electro Microscopy results were correlated to X-ray phase analysis and density measurements. The progressively developed microstructure was used to interpret the densification behavior of SiAlON. Photomicrographs of microstructures are shown.

Yeh, H. C.↗
NASA NTRS1999

Novel Directional Solidification Processing of Hypermonotectic Alloys

Gravity driven separation precludes uniform microstructural development during controlled directional solidification (DS) processing of hypermonotectic alloys. It is well established that liquid/liquid suspensions, in which the respective components are immiscible and have significant density differences, can be established and maintained by utilizing ultrasound. A historical introduction to this work is presented with the intent of establishing the basis for applying the phenomena to promote microstructural uniformity during controlled directional solidification processing of immiscible mixtures. Experimental work based on transparent organics, as well as salt systems, will be presented in view of the processing parameters.

Grugel, Richard N.↗
NASA NTRS1992

Microstructural observations in rapidly-solidified and heat-treated Ni3Al-Cr alloys

The microstructural development following heat treatments of several rapidly-solidified Ni3Al-Cr and Ni3Al-Cr-B alloys is presented. Depending on composition, the as-solidified samples were either 100 percent gamma-prime phase - in the form of fine antiphase domains (APD) - or a mixture of gamma-prime (APDs) and beta phases. Upon annealing, the as-solidified microstructures transform to either APD-free gamma-prime or mixtures of gamma and gamma-prime phases. For those compositions where the quenched microstructures were 100 percent gamma-prime it was observed that APD coarsening followed conventional grain-growth kinetics, but when gamma phase precipitated on the APD boundaries the rate constant changed abruptly while the time exponent remained unaffected. It was also found that alloys containing critical amounts of chromium and boron are susceptible to precipitation of the boride Cr5B3.

Carro, G.↗
NASA NTRS1996

Fossilization processes in siliceous thermal springs: trends in preservation along thermal gradients

To enhance our ability to extract palaeobiological and palaeoenvironmental information from ancient thermal spring deposits, we have studied the processes responsible for the development and preservation of stromatolites in modern subaerial thermal spring systems in Yellowstone National Park (USA). We investigated specimens collected from silica-depositing thermal springs along the thermal gradient using petrographic techniques and scanning electron microscopy. Although it is known that thermophilic cyanobacteria control the morphogenesis of thermal spring stromatolites below 73 degrees C, we have found that biofilms which contain filamentous thermophiles contribute to the microstructural development of subaerial geyserites that occur along the inner rims of thermal spring pools and geyser effluents. Biofilms intermittently colonize the surfaces of subaerial geyserites and provide a favoured substrate for opaline silica precipitation. We have also found that the preservation of biotically produced microfabrics of thermal spring sinters reflects dynamic balances between rates of population growth, decomposition of organic matter, silica deposition and early diagenesis. Major trends in preservation of thermophilic organisms along the thermal gradient are defined by differences in the mode of fossilization, including replacement, encrustation and permineralization.

NASA Discipline Exobiology↗
NASA NTRS2000

Solidification Processing of Immiscible Liquids in the Presence of Applied Ultrasonic Energy

Uniform microstructural development during solidification of immiscible liquids on Earth is hampered by inherent density differences between the phases. Microgravity processing minimizes settling but segregation still occurs due to gravity independent wetting and coalescence phenomena. Experiments with the transparent organic, metal analogue, succinonitrile-glycerol system were conducted in conjunction with applied ultrasonic energy. The processing parameters associated with this technique have been evaluated in view of optimizing dispersion uniformity. Experimental results to evaluate microstructural phase distributions, based on other liquid-liquid immiscibility systems, will also be presented.

Kim, Shinwood↗
NASA NTRS2000

BUNDLE: A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

Carrasquillo, Edgar J.↗
NASA NTRS2001

BUNDLE - A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

Carrasquillo, Edgar J.↗
NASA NTRS1998

Semiconductors: In Situ Processing of Photovoltaic Devices

Current proposals for developing an extended human presence on the Moon and Mars increasingly consider the processing of nonterrestrial materials essential for keeping the Earth launch burden reasonable. Utilization of in situ resources for construction of lunar and Mars bases will initially require assessment of resource availability followed by the development of economically acceptable and technically feasible extraction processes. In regard to materials processing and fabrication, the lower gravity level on the Moon (0.125 g) and Mars (0.367 g) will dramatically change the presently accepted hierarchy of materials in terms of specific properties, a factor that must be understood and exploited. Furthermore, significant changes are expected in the behavior of liquid materials during processing. In casting, for example, mold filling and associated solidification processes have to be reevaluated. Finally, microstructural development, and therefore material properties, presently being documented through ongoing research in microgravity science and applications, need to be understood and scaled to the reduced gravity environments.

Curreri, Peter A.↗
NASA NTRS1999

In-Situ Production of Solar Power Systems for Exploration

Current proposals for developing an extended human presence, beyond space stations, on the Moon and Mars increasingly consider the processing of non-terrestrial materials essential for keeping the Earth launch burden reasonable. Utilization of in-situ resources for construction of lunar and Mars bases will initially require assessment of resource availability followed by the development of economically acceptable and technically feasible extractive processes. In regard to materials processing and fabrication the lower gravity level on the Moon (0.125 g) and Mars (0.367 g) will dramatically change the presently accepted hierarchy of materials in terms of specific properties, a factor which must be understood and exploited. Furthermore, significant changes are expected in the behavior of liquid materials during processing. In casting, for example, mold filling and associated solidification processes have to be reevaluated. Finally microstructural development and therefore material properties, presently being documented through on-going research in microgravity science and applications, needs to be understood and scaled to the reduced gravity environments. One of the most important elements of a human planetary base is power production. Lunar samples and geophysical measurements returned by the Apollo missions provide detailed data on the composition and physical characteristics of the lunar materials and environment. Based on this knowledge and extrapolations of terrestrial industrial experience it is clear that several types of solar-to-electric converters can be manufactured on the Moon. It is conceivable that well over 90% of a solar-to- electric power system could be made from lunar materials. Production and utilization of photovoltaic devices for solar energy production on Earth is primarily driven by the market economy. On Earth a production plant for photovoltaic devices is intimately linked to the planets massive industrial base. A selection of off the shelf refined materials are available as well as cheap fast transportation on demand. The processes takes place (except for the few seconds reprieve in shot towers etc.) under one gravity, with solar radiation significantly modulated by weather, and under conditions where one atmosphere is free and high vacuum is cumbersome and expensive. Off Earth, on lunar or Mars bases, the cost of photovoltaic power is driven by transport costs - Earth launch, deep space transport, landing on the planetary surface. Thus there is a premium for processes that are materials self-sufficient or for closed loop in-situ processes. The lack of differentiated ores on the Moon, and lack of explored minerals on Mars and interplanetary space give a premium to universal/non-ore-specific mineral extractive processes. Initially a semiconductor/photovoltaic production facility will build on no conveniently located industrial base, further increasing the premium on closed loop self sufficient processes.

Curreri, Peter A.↗
NASA NTRS1998

In situ Resource Utilization for Processing of Metal Alloys on Lunar and Mars Bases

Current plans for practical missions leading to a sustained human presence on our Moon and Mars rely on utilizing their in situ resources. Initially, resource availability must be assessed followed by the development of economically acceptable and technically feasible extractive processes. In regard to metals processing and fabrication, the lower gravity level on the Moon (0.125 g) and Mars (0.369 g) will dramatically change the presently accepted hierarchy of materials in terms of specific properties, a factor which must be understood and exploited. Furthermore, significant changes are expected in the behavior of liquid metals during processing. In metal casting, for example, mold filling and associated solidification processes have to be reevaluated. Finally, microstructural development and therefore material properties, presently being documented through ongoing research in microgravity science and applications, needs to be understood and scaled to the reduced gravity environments. These and other issues are addressed in this paper.

Stefanescu, D. M.↗
NASA NTRS2015

Printing Outside the Box: Additive Manufacturing Processes for Fabrication of Large Aerospace Structures

To achieve NASA's mission of space exploration, innovative manufacturing processes are being applied to the fabrication of propulsion elements. Liquid rocket engines (LREs) are comprised of a thrust chamber and nozzle extension as illustrated in figure 1 for the J2X upper stage engine. Development of the J2X engine, designed for the Ares I launch vehicle, is currently being incorporated on the Space Launch System. A nozzle extension is attached to the combustion chamber to obtain the expansion ratio needed to increase specific impulse. If the nozzle extension could be printed as one piece using free-form additive manufacturing (AM) processes, rather than the current method of forming welded parts, a considerable time savings could be realized. Not only would this provide a more homogenous microstructure than a welded structure, but could also greatly shorten the overall fabrication time. The main objective of this study is to fabricate test specimens using a pulsed arc source and solid wire as shown in figure 2. The mechanical properties of these specimens will be compared with those fabricated using the powder bed, selective laser melting technology at NASA Marshall Space Flight Center. As printed components become larger, maintaining a constant temperature during the build process becomes critical. This predictive capability will require modeling of the moving heat source as illustrated in figure 3. Predictive understanding of the heat profile will allow a constant temperature to be maintained as a function of height from substrate while printing complex shapes. In addition, to avoid slumping, this will also allow better control of the microstructural development and hence the properties. Figure 4 shows a preliminary comparison of the mechanical properties obtained.

Babai, Majid↗
NASA NTRS1975

Ferromagnetic phase-mass equivalence and lunar sample magnetic remanence

Man-made alloy spheres simulating the compositions of particles found in the lunar soil and weighting approximately 10 mg are shown to be equivalent, insofar as remanence intensity and demagnetization stability are concerned, to more than about 10 billion submicrometer spherical iron particles. The large particles not only contain large stable magnetic remanence, but when the polished surfaces of these particles are etched and carefully studied, they provide useful petrogenetic information, imply the mechanism of magnetization, the time-temperature history, and outline the format for possible paleointensity analysis. The intensity and stability of the remanence in these large spheres is related to the microstructure developed during rapid cooling.

Wasilewski, P. J.↗
NASA NTRS1979

Some TEM observations of Al2O3 scales formed on NiCrAl alloys

The microstructural development of Al2O3 scales on NiCrAl alloys has been examined by transmission electron microscopy. Voids were observed within grains in scales formed on a pure NiCrAl alloy. Both voids and oxide grains grew measurably with oxidation time at 1100 C. The size and amount of porosity decreased towards the oxide-metal growth interface. The voids resulted from an excess number of oxygen vacancies near the oxidemetal interface. Short-circuit diffusion paths were discussed in reference to current growth stress models for oxide scales. Transient oxidation of pure, Y-doped, and Zr-doped NiCrAl was also examined. Oriented alpha-(Al, Cr)2O3 and Ni(Al, Cr)2O4 scales often coexisted in layered structures on all three alloys. Close-packed oxygen planes and directions in the corundum and spinel layers were parallel. The close relationship between oxide layers provided a gradual transition from initial transient scales to steady state Al2O3 growth.

Smialek, J.↗