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Gradient-tempering process increases fracture toughness and resistance to stress-corrosion cracking of ball-bearing races made of hard, strong steels and subject to high installation stresses and operation in corrosive media. Also used in other applications in which local toughening of high-strength/low-toughness materials required.
Cold working and double aging yield high strength without sacrifice of resistance to corrosion. Report presents data on mechanical properties and stress-corrosion resistance of triple-melted, solution-treated, work-strengthened, direct-double-aged Inconel(R) 718 alloy. Triple melting consists of vacuum induction melting, electro-slag remelting, and vacuum arm remelting. Data indicate advance in processing of large-diameter bars. New process increases yield strength without reducing the elongation, reduction of area, and grain size.
This report is a critical review of both environment-enhanced fatigue crack propagation data and the predictive capabilities of crack growth rate models. This information provides the necessary foundation for incorporating environmental effects in NASA FLAGRO and will better enable predictions of aerospace component fatigue lives. The review presents extensive literature data on 'stress corrosion cracking and corrosion fatigue.' The linear elastic fracture mechanics approach, based on stress intensity range (Delta(K)) similitude with microscopic crack propagation threshold and growth rates, provides a basis for these data. Results are presented showing enhanced growth rates for gases (viz., H2 and H2O) and electrolytes (e.g. NaCl and H2O) in aerospace alloys including: C-Mn and heat treated alloy steels, aluminum alloys, nickel-based superalloys, and titanium alloys. Environment causes purely time-dependent accelerated fatigue crack growth above the monotonic load cracking threshold (KIEAC) and promotes cycle-time dependent cracking below (KIEAC). These phenomenon are discussed in terms of hydrogen embrittlement, dissolution, and film rupture crack tip damage mechanisms.
Ni-based structural alloys in molten salt environments often experience simultaneous mechanical loading and corrosive attack, yet the mechanisms governing stress-corrosion interactions remain unclear. Prior studies largely emphasize tensile stress, while the role of compressive stress has received limited attention. Here, reactive molecular dynamics simulations are used to investigate the coupled effects of applied strain and corrosion in Ni 0.75 Cr 0.25 exposed to molten FLiNaK at 800 °C. A Σ5(210) grain boundary model is subjected to tensile (+4%) to compressive (−4%) uniaxial strains, and corrosion behavior is evaluated through fluorine adsorption, charge redistribution, and grain boundary evolution. Tensile strain accelerates intergranular corrosion susceptibility by reducing local atomic packing through elastic dilation and increasing excess free volume at the grain boundary, which enhances atomic mobility and salt infiltration. In contrast, compressive strain can suppress corrosion by promoting the formation of a ridge-like surface layer along the grain boundary, limiting salt access to the underlying alloy. These results provide atomistic insight into how stress states influence grain boundary corrosion in molten salts.
The fundamental principles allowing design of stainless bearing steels with enhanced toughness and stress corrosion resistance has involved both investigation of basic phenomena in model alloys and evaluation of a prototype bearing steel based on a conceptual design exercise. Progress in model studies has included a scanning Auger microprobe (SAM) study of the kinetics of interfacial segregation of embrittling impurities which compete with the kinetics of alloy carbide precipitation in secondary hardening steels. These results can define minimum allowable carbide precipitation rates and/or maximum allowable free impurity contents in these ultrahigh strength steels. Characterization of the prototype bearing steel designed to combine precipitated austenite transformation toughening with secondary hardening shows good agreement between predicted and observed solution treatment response including the nature of the high temperature carbides. An approximate equilibrium constraint applied in the preliminary design calculations to maintain a high martensitic temperature proved inadequate, and the solution treated alloy remained fully austenitic down to liquid nitrogen temperature rather than transforming above 200 C. The alloy can be martensitically transformed by cryogenic deformation, and material so processed will be studied further to test predicted carbide and austenite precipitation behavior. A mechanistically-based martensitic kinetic model was developed and parameters are being evaluated from available kinetic data to allow precise control of martensitic temperatures of high alloy steels in future designs. Preliminary calculations incorporating the prototype stability results suggest that the transformation-toughened secondary-hardening martensitic-stainless design concept is still viable, but may require lowering Cr content to 9 wt. pct. and adding 0.5 to 1.0 wt. pct. Al. An alternative design approach based on strain-induced martensitic transformation during cryogenic forming, thus removing the high martensitic constraint, may permit alloy compositions offering higher fracture roughness.
A technique has been developed to design a maximum efficiency reliable pressure vessel of given geometry and service life. The technique for ensuring reliability of the minimum weight vessel relies on the application of linear elastic fracture mechanics and fracture mechanics concepts. The resultant design incorporates potential fatigue and stress corrosion crack extension during service of a worst case initial flaw. Maximum stress for safe life is specified by the design technique, thereby minimizing weight. Ratios of pressure and toughness parameters are employed to avoid arbitrary specification of design stress level which would lead to a suboptimum design.
A dynamic fatigue study was performed on a Li2O-Al2O3-SiO2 glass-ceramic in order to assess its susceptibility to delayed failure. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions for optical elements made from this material. The material has reasonably good resistance (N = 20) to stress corrosion in ambient conditions. Analysis also indicated the elements should survive applied stresses incurred during grinding and polishing operations.
Localized corrosion in welded samples of 2219-T87 Al alloy (2319 filler), 2090 Al-Li alloy (4043 and 2319 fillers), and 2195 Al-Li alloy (4043 and 2319 fillers) has been investigated using the relatively new scanning reference electrode technique. The weld beads are cathodic in all cases, leading to reduced anode/cathode ratios. A reduction in anode/cathode ratio leads to an increase in the corrosion rates of the welded metals, in agreement with results obtained in previous electrochemical and stress corrosion studies involving the overall corrosion rates of welded samples. The cathodic weld beads are bordered on both sides by strong anodic regions, with high propensity for corrosion.
This report documents the microstructural and surface characterization of two high-fluence baffle-former bolts (BFBs) harvested from a commercial pressurized water reactor (PWR) after nearly four decades of service. These bolts experienced extreme conditions including high neutron fluence, elevated temperatures, corrosive primary water, and sustained mechanical loads, all of which contribute to degradation mechanisms such as irradiation-assisted stress corrosion cracking (IASCC). Using scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), the study assessed bulk and near-surface microstructures, grain boundary characteristics, and in-service oxide layers. The results revealed significant differences between bolts exposed to 41 dpa and 29 dpa, including differences in recrystallization extent, deformation structures, and oxidation morphology. These findings establish critical baseline data for integration with advanced synchrotron-based high-energy X-ray microscopy (HEXM) and computational crystal plasticity models. Ultimately, the work supports improved mechanistic understanding and predictive capability regarding the long-term performance of reactor core internal components.
The possible role of activated processes in seismic attenuation is investigated. In this study, a solid is modeled by a parallel and series configuration of dashpots and springs. The contribution of stress and temperature activated processes to the long term dissipative behavior of this system is analyzed. Data from brittle rock deformation experiments suggest that one such process, stress corrosion cracking, may make a significant contribution to the attenuation factor, Q, especially for long period oscillations under significant tectonic stress.
The objective of this project was to examine the corrosion resistance of 316L stainless steel in several urine pre-treat solutions. Four solutions were examined: untreated urine (control); urine pretreated with oxone (potassium peroxymonosulfate sulfate); urine pretreated with sodium hypochlorite (NaOCl); and urine pretreated with ozone (O3). In accordance with current procedures, all solutions but the control were acidified to a pH of 2.5 using sulfuric acid--this suppresses the generation of ammonia in the solutions and is intended to limit microbial growth. Welded and unwelded coupons were exposed to each solution. In addition, Titanium coupons (welded and unwelded) were exposed to biologically active environmental control and life support system (ECLSS) water. Microbial attachment and biofilm growth were monitored. Ozone was examined as a biocide/oxidizer/corrosion preventative (simultaneous addition) and as a remediation method (added one week after exposure). In an unrelated effort, HP 9-4-30 coupons were exposed to biologically active solutions. Corrosion rates for welded and unwelded samples were determined--results were correlated to the ongoing HP 9-4-30 weldment stress corrosion study.
To assess the stress corrosion susceptibility of a machinable glass-ceramic, its dynamic fatigue behavior was investigated by measuring its strength as a function of stress rate. Fracture mechanics techniques were used to analyse the results for the purpose of making lifetime predictions for components of this material. This material was concluded to have only moderate resistance to stress in ambient conditions. The effects of specimen size on strength were assessed for the material used in this study: it was concluded that the Weibull edge-flaw scaling law adequately describes the observed strength-size relationship.
Advanced post-irradiation examination (PIE) techniques are required to design new or improved nuclear materials, characterize, and understand in-core behavior of fuel and materials, and support the qualification of new reactor materials. The Nuclear Science User Facilities (NSUF) is the U.S. Department of Energy Office of Nuclear Energy's only designated nuclear science user facility. NSUF provides researchers access to PIE capabilities at Idaho National Laboratory and at a diverse mix of university, national laboratory and industrial partner institutions. The PIE capabilities include novel destructive and non-destructive techniques for radiation damage characterization, such as advanced diffraction techniques (X-ray, electron, or neutron) coupled to extreme environments; in-situ observation of microstructural evolution under irradiation; in-situ irradiation to monitor corrosive attack in coolant environments; in-situ irradiation and mechanical testing; and test methods for synergistic effects of superimposed extreme environments (temperature, irradiation, stress, corrosion) on materials behaviors. This talk will provide an overview of NSUF PIE capabilities.
The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program continues a high level of activity. Progress achieved between 1 Jan. and 30 Jun. 1993 is reported. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The following projects are addressed: environmental fatigue of Al-Li-Cu alloys; mechanisms of localized corrosion and environmental fracture in Al-Cu-Li-Mg-Ag alloy X2095 and compositional variations; the effect of zinc additions on the precipitation and stress corrosion cracking behavior of alloy 8090; hydrogen interactions with Al-Li-Cu alloy 2090 and model alloys; metastable pitting of aluminum alloys; cryogenic fracture toughness of Al-Cu-Li + In alloys; the fracture toughness of Weldalite (TM); elevated temperature cracking of advanced I/M aluminum alloys; response of Ti-1100/SCS-6 composites to thermal exposure; superplastic forming of Weldalite (TM); research to incorporate environmental effects into fracture mechanics fatigue life prediction codes such as NASA FLAGRO; and thermoviscoplastic behavior.
The effect of a high level of chloride content (800 ppm) in MON-1 propellant on the crack growth properties of seven materials was investigated. Sustained load tests were conducted at 49 C (120 F) temperature with thin gauge tensile specimens having a semi-elliptical surface flaw. Alloys included aluminum 1100, 3003, 5086 and 6061; corrosion resistant steel types A286 and 347; and titanium 6Al-4V. The configurations tested with precracked flaws exposed to MON-1 were: parent or base metal, center weld, and heat affected zone. It was concluded that this chloride level in MON-1 does not affect the stress corrosion, crack growth properties of these alloys after 1000 hour exposure duration under high stresses.
Ultra Low Expansion (ULE) glass is used in a number of applications which require a low thermal expansion coefficient. One such application is telescope mirror elements. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure. Delayed failure, due to stress corrosion can significantly shorten the lifetime of a glass article. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct time-to-failure diagrams for both 230/270 ground and optically polished samples. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing materials with successively smaller grinding media. This resulted in an increase in the strength of the optic during the grinding and polishing sequence. There was also an increase in the lifetime due to grinding and polishing. It was found that using the fatigue parameters determined from the 230/270 grit surface are not significantly different from the optically polished values. Although the lower bound of the polished samples is more conservative, neither time-to-failure curves lie beyond the upper or lower bound of the confidence limits. Therefore, designers preferring conservative limits could use samples without residual stress present (polished samples) to determine the fatigue parameters and inert Weibull parameters from samples with the service condition surface, to determine time-to-failure of the optical element.
A Mode I fracture specimen and loading method has been developed which permits the observation of stable crack extension in monolithic and in situ toughened ceramics. The developed technique was used to conduct room temperature tests on commercial grade alumina (Coors' AD-995) and silicon nitride (Norton NC-132). The results of these tests are reported. Crack growth for the alumina remained subcritical throughout testing revealing possible effects of environmental stress corrosion. The crack growth resistance curve for the alumina is presented. The silicon nitride tests displayed a series of stable (slow) crack growth segments interrupted by dynamic (rapid) crack extension. Crack initiation and arrest stress intensity factors, K(sub Ic) and K(sub Ia), for silicon nitride are reported. The evolution of the specimen design through testing is briefly discussed.
A program was conducted at Kennedy Space Center from February 1968 to February 1971 to evaluate the performance of austenitic stainless steel alloys used in fluid systems lines. For several years, there had been numerous failures of stainless steel hardware caused by pitting and stress corrosion cracking. Several alloys were evaluated for effectiveness of certain sacrificial-type protective coverings in preventing corrosion failures. Samples were tested in specially designed racks placed 91 meters (100 yards) above high-tide line at Cape Kennedy. It is concluded that: (1) unprotected tubing samples showed evidence of pitting initiation after 2 weeks; (2) although some alloys develop larger pits than others, it is probable that the actual pitting rate is independent of alloy type; (3) the deepest pitting occurred in the sheltered part of the samples; and (4) zinc-rich coatings and an aluminum-filled coating have afforded sacrificial protection against pitting for at least 28 months. It is believed that a much longer effective coating life can be expected.