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DOE OSTI2021

Accelerated Creep Test Qualification of Creep-Resistance Using the Wilshire–Cano–Stewart Constitutive Model and Stepped Isostress Method

In this paper, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire–Cano–Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing is a long-term continuous process; in fact, the ASME B&PV III requires that 10,000+ h of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The SSM has been developed, which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750 °C and predictions are compared to conventional creep testing data. The WCS model has proven to make long-term predictions for stress-rupture, MCSR, creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are postaudit validated using the National Institute of Material Science database. Similarly, the MCSR predictions are compared from previous studies. Finally, the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and industrial gas turbines.

42 ENGINEERING↗

DOE OSTI2021

Comprehensive Margin Assessment of the ASME Section III, Division 5, Class A Primary Load Design Rules

This report provides a comprehensive margin assessment of the ASME Section III, Division 5, Subsection HB, Subpart B rules for the design of high temperature reactor components against load controlled stress limits. These rules, often called the Code primary load design rules, provide protection against creep rupture and plastic collapse under steady conditions. The method adopted here is to compare the deterministic ASME design life, according to the primary load design rules, against the expected, statistical service life of the component, considering creep rupture as the relevant failure mode. The report provides the design margin of the ASME rules in terms of the probability of premature failure -- the probability that the component fails in service before reaching the ASME design life. To complete this assessment, the report describes the development of a statistical creep life assessment procedure accounting for variations in the component loading, material creep rate, and the material rupture time. This includes a novel method for correlating creep rupture data using a Gaussian process accounting for heat-to-heat variation in the Larson-Miller time-temperature parameter. The report applies the complete margin assessment process to quantify the design margin inherent in the ASME primary load design rules as a function of temperature for relevant component geometries and materials. The overall conclusion is that the ASME rules are conservative, providing designs with very small probability of premature failure, but some optimization of the Code design rules is possible to provide a more uniform design margin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Characterization of Precipitation-Strengthening Heat-Resistant Austenitic Stainless Steels for Life-Prediction Modeling

In this study, the role of minor alloying additions in 347H stainless steels (UNS34709, ASTM A240/240M) on creep-rupture properties at 650-750°C and microstructure evolution during isothermal exposure at 750°C has been investigated, aiming to provide the experimental dataset as boundary conditions of physics-based modeling for material/component life prediction. Four different 347H heats containing various amounts of boron and nitrogen additions were prepared and evaluated. The combined additions of B and N are found to stabilize the strengthening secondary M23C6 carbides and retarding the transition from M23C6 to sigma phase precipitates during thermal exposure. The observed kinetics of microstructure evolution reasonably explains the improvement of creep-rupture properties of 347H stainless steels with the B and N additions.

Yamamoto, Yukinori↗

NASA NTRS1972

Friction welding.

Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

Moore, T. J.↗

NASA NTRS1974

Examination of the influence of coatings on thin superalloy sections. Volume 2: Detailed procedures and data

The effects of an aluminide coating, Codep B-1, and of section thickness were investigated on two cast nickel base superalloys, Rene 80 and Rene 120. Cast section thicknesses ranged from 0.038 cm to 0.15 cm. Simulated engine exposures for 1000 hours at 899C or 982C in a jet fuel burner rig with cyclic air cooling were studied, as were the effects of surface machining before coating and re-machining and re-coating after exposures. The properties evaluated included tensile at room temperature., 871C and 982C, stress rupture at 760C, 871C, 982C and 1093C, high cycle mechanical fatigue at room temperature., and thermal fatigue with a 1093C peak temperature. Thin sections had tensile strengths similar to standard size bars up to 871C and lower strengths at 982C and above, with equivalent elongation, and stress rupture life was lower for thin sections at all test conditions. The aluminide coating lowered tensile and rupture strengths up to 871C, with greater effects on thinner specimens. Elevated temperature exposure lowered tensile and rupture strengths of thinner specimens at the lower test temperatures. Surface machining had little effect on properties, but re-machining after exposure reduced thickness and increased metallurgical changes enough to lower properties at most test conditions.

Kaufman, M.↗

NASA NTRS1981

Development of materials and process technology for dual alloy disks

Techniques for the preparation of dual alloy disks were developed and evaluated. Four material combinations were evaluated in the form of HIP consolidated and heat treated cylindrical and plate shapes in terms of elevated temperature tensile, stress rupture and low cycle fatigue properties. The process evaluation indicated that the pe-HIP AF-115 rim/loose powder Rene 95 hub combination offered the best overall range of mechanical properties for dual disk applications. The feasibility of this dual alloy concept for the production of more complex components was demonstrated by the scale up fabrication of a prototype CFM-56 disk made from this AF-115/Rene 95 combination. The hub alloy ultimate tensile strength was approximately 92 percent of the program goal of 1520 MPa (220 ksi) at 480 C (900 F) and the rim alloy stress rupture goal of 300 hours at 675 C (1250 F)/925 MPa (134 ksi) was exceeded by 200 hours. The low cycle fatigue properties were equivalent to those exhibited by HIP and heat treated alloys. There was an absence of rupture notch sensitivity in both alloys. The joint tensile properties were approximately 85 percent of the weaker of the two materials (Rene 95) and the stress rupture properties were equivalent to those of the weaker of the two materials (Rene 95).

Marder, J. M.↗

NASA NTRS1983

Feasibility of water injection into the turbine coolant to permit gas turbine contingency power for helicopter application

A system which would allow a substantially increased output from a turboshaft engine for brief periods in emergency situations with little or no loss of turbine stress rupture life is proposed and studied analytically. The increased engine output is obtained by overtemperaturing the turbine; however, the temperature of the compressor bleed air used for hot section cooling is lowered by injecting and evaporating water. This decrease in cooling air temperature can offset the effect of increased gas temperature and increased shaft speed and thus keep turbine blade stress rupture life constant. The analysis utilized the NASA-Navy-Engine-Program or NNEP computer code to model the turboshaft engine in both design and off-design modes. This report is concerned with the effect of the proposed method of power augmentation on the engine cycle and turbine components. A simple cycle turboshaft engine with a 16:1 pressure ratio and a 1533 K (2760 R) turbine inlet temperature operating at sea level static conditions was studied to determine the possible power increase and the effect on turbine stress rupture life that could be expected using the proposed emergency cooling scheme. The analysis showed a 54 percent increse in output power can be achieved with no loss in gas generator turbine stress rupture life. A 231 K (415 F) rise in turbine inlet temperature is required for this level of augmentation. The required water flow rate was found to be .0109 kg water per kg of engine air flow.

Vanfossen, G. J.↗

NASA NTRS1982

The effects of Ni, Mo, Ti and Si on the mechanical properties of Cr free Mn steel (Fe-25Mn-5Al-2C)

The FeMnAlC alloys may hold potential as Cr-free replacements for high strategic material iron base superalloys, but little is known about their intermediate temperature (650 C to 870 C) mechanical properties. The effects of alloying elements on the mechanical properties of model FeMnAlC alloys were studied. Results showed that modified FeMnAlC alloys had promising short term, intermediate temperature properties but had relatively poor stress rupture lives at 172 MPa and 788 C. Room temperature and 788 C tensile strength of FeMnAlC alloys were better than common cast stainless steels. Changes in room temperature tensile and 788 C tensile strength and ductility, and 788 C stress rupture life were correlated with changes in Ni, Mo, Ti, and Si levels due to alloying effects on interstitial carbon levels and carbide morphology. Fe-25Mn-5Al-2C had a very poor stress rupture life at 172 MPa and 788 C. Addition of carbide-forming elements improved the stress rupture life.

Schuon, S. R.↗

NASA NTRS1983

Producibility of fibrous refractory composite insulation, FRCI 40-20

Fibrous Refractory Composite Insulation (FRCI) is a NASA-developed, second generation, reusable heat-shield material that comprises a mixture of aluminoborosilicate fibers, silica fibers, and silicon carbide. Under NASA contract, a program was conducted to demonstrate the capability for manufacturing FRCI 40-20 billets. A detailed fabrication procedure was written and validated by testing specimens from the first two billets. The material conformed to NASA requirements for density, tensile strength, modulus of rupture, thermal expansion, cristobalite content, and uniformity. Twenty-four billets were prepared to provide 20 deliverable articles. Production billets were checked for density, modulus of rupture, cristobalite content, and uniformity. Billet density ranged from 309.48 to 332.22 kg/cu m (19.32 to 20.74 lb/cu ft) and modulus of rupture from 4690 to 10,140 kPa (680 to 1470 psi). Cristobalite content was less than 1 percent. A Weibull analysis of modulus-of-rupture data indicated a 1.5 percent probability for failure below the specified strength of 4480 kPa (650 psi).

Strauss, E. L.↗

NASA NTRS1992

Long-life assessment of graphite epoxy materials for Space Station Freedom pressure vessels

Graphite/epoxy composite overwrapped pressure vessels are being considered for use on Space Station Freedom because of their light weight and high efficiency. These composite pressure vessels weigh roughly one-third of comparable all-metal aluminum pressure vessels, and could result in a 15,000-lb weight saving for the propulsion and fluid management and distribution systems. These vessels must resist failures under sustained pressure loads for crew safety considerations and adequate protection of the space structure during their 30-yr life. Weibull statistical analysis techniques have been applied, and a model developed, for predicting long-term stress-rupture behavior based on published short-term test data on composite strands and pressure vessels. Graphite/epoxy materials are calculated to have a 99.99-percent probability of surviving stress rupture for 30 yr under a sustained load of 50 percent ultimate failure strength. Stress-rupture lifetimes are predicted to increase as the size of the pressure vessels increases in support of the viscoelastic load-transfer mechanism proposed for stress rupture of fiber/epoxy composite materials.

Thomas, Donald A.↗

NASA NTRS2000

Room and Elevated Temperature Tensile Properties of Single Tow Hi-Nicalon, Carbon Interphase, CVI SiC Matrix Minicomposites

Single tow Hi-Nicalon(TM), C interphase, CVI SiC matrix minicomposites were tested in tension at room temperature, 700 C, 950 C, and 1200 C in air. Monotonic loading with modal acoustic emission monitoring was performed at room temperature in order to determine the dependence of matrix cracking on applied load. Modal acoustic emission was shown to correlate directly with the number of matrix cracks formed. Elevated temperature constant load stress-rupture and low-cycle fatigue experiments were performed on precracked specimens. The elevated temperature rupture behavior was dependent on the precrack stress, the lower precrack stress resulting in longer rupture life for a given stress. It was found that the rupture lives of C-interphase Hi-Nicalon(TM) minicomposites were superior to C-interphase Ceramic Grade Nicalon(TM) minicomposites and inferior to those of BN-interphase Hi-Nicalon(TM) minicomposites.

Martinez-Fernandez, J.↗

NASA NTRS1998

The Surface Displacement Field of the November 8, 1997, Mw7.6 Manyi (Tibet) Earthquake Observed with ERS InSAR Data

ERS2 radar data acquired before and after the Mw7.6, Manyi (Tibet) earthquake of November 8, 1997, provide geodetic information about the surface displacement produced by the earthquake in two ways. (1) The sub-pixel geometric adjustment of the before and after images provides a two dimensional offset field with a resolution of approx, 1m in both the range (radar line of sight) and azimuth (satellite track) directions. Comparison of offsets in azimuth and range indicates that the displacement along the fault is essentially strike-slip and in a left-lateral sense. The offset map reveals a relatively smooth and straight, N78E surface rupture that exceeds 150 km in length, consistent with the EW plane of the Harvard CMT solution. The rupture follows the trace of a quaternary fault visible on satellite imagery (Tapponnier and Molnar, 1978; Wan Der Woerd, pers. comm.). (2) Interferometric processing of the SAR data provides a range displacement map with a precision of a few millimeters. The slip distribution along the rupture reconstructed from the range change map is a bell-shaped curve in the 100-km long central section of the fault with smaller, local maxima near both ends. The curve shows that the fault slip exceeds 2.2 m in range, or 6.2 in strike-slip, along a 30-km long section of the fault and remains above 1 m in range, approx. 3 m strike-slip, along most of its length. Preliminary forward modeling of the central section of the rupture, assuming a uniform slip distribution with depth, indicates that the slip occur-red essentially between 0 and the depth of 10 km, consistent with a relatively shallow event (Velasco et al., 1998).

Peltzer, G.↗

NASA NTRS2002

Hypergolic Ignitor Assembly

An ignitor for use with the MC-I rocket engine has a cartridge bounded by two end caps with rupture disc assemblies connected thereto. A piston assembly within the cartridge moves from one end of the cartridge during the ignition process. The inlet of the ignitor communicates with a supply taken from the discharge of the fuel pump. When the pump is initially started, the pressure differential bursts the first rupture disc to begin the movement of the piston assembly toward the discharge end. The pressurization of the cartridge causes the second rupture to rupture and hypergolic fluid contained within the cartridge is discharged out the outlet. Once the piston assembly reaches the discharge end of the cartridge, purge grooves allow for fuel and remaining hypergolic fluid, to be discharged out the ignitor outlet into the combustion chamber to purge the ignitor of any remaining hypergolic fluid.

Eric S Taylor↗

NASA NTRS1997

Oxidation Embrittlement Observed in SiC/SiC Composites

As part of a comprehensive materials characterization program at the NASA Lewis Research Center, tensile creep-rupture tests were performed on a SiC-fiber-reinforced SiC-matrix composite. The results of these tests and subsequent analysis revealed an oxidation embrittlement phenomena that occurs readily at a discreet temperature range below the maximum use temperature. The graph shows rupture lives for a creep stress of 83 MPa as a function of temperature. Note that the rupture time is constant at an intermediate temperature range of 700 to 982 C. This graph also shows the failure location, as measured from the center of the specimen. Whereas for temperatures of 500 to 700 C, failure occurred in the specimen gage section; at higher temperatures, the failure location migrated toward the cooled grip ends. Although the results initially suggested that the test procedure was influencing the measured creep rupture lives and driving the failure location out of the gage section, subsequent experiments and thermal stress analyses verified the robustness of the test method employed.

Verrilli, Michael J.↗

NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗

NASA NTRS2002

A Nonlinear Viscoelastic Model for Ceramics at High Temperatures

High-temperature creep behavior of ceramics is characterized by nonlinear time-dependent responses, asymmetric behavior in tension and compression, and nucleation and coalescence of voids leading to creep rupture. Moreover, creep rupture experiments show considerable scatter or randomness in fatigue lives of nominally equal specimens. To capture the nonlinear, asymmetric time-dependent behavior, the standard linear viscoelastic solid model is modified. Nonlinearity and asymmetry are introduced in the volumetric components by using a nonlinear function similar to a hyperbolic sine function but modified to model asymmetry. The nonlinear viscoelastic model is implemented in an ABAQUS user material subroutine. To model the random formation and coalescence of voids, each element is assigned a failure strain sampled from a lognormal distribution. An element is deleted when its volumetric strain exceeds its failure strain. Element deletion has been implemented within ABAQUS. Temporal increases in strains produce a sequential loss of elements (a model for void nucleation and growth), which in turn leads to failure. Nonlinear viscoelastic model parameters are determined from uniaxial tensile and compressive creep experiments on silicon nitride. The model is then used to predict the deformation of four-point bending and ball-on-ring specimens. Simulation is used to predict statistical moments of creep rupture lives. Numerical simulation results compare well with results of experiments of four-point bending specimens. The analytical model is intended to be used to predict the creep rupture lives of ceramic parts in arbitrary stress conditions.

Powers, Lynn M.↗

NASA NTRS2007

Condition Assessment of Kevlar Composite Materials Using Raman Spectroscopy

This viewgraph presentation includes the following main concepts. Goal: To evaluate Raman spectroscopy as a potential NDE tool for the detection of stress rupture in Kevlar. Objective: Test a series of strand samples that have been aged under various conditions and evaluate differences and trends in the Raman response. Hypothesis: Reduction in strength associated with stress rupture may manifest from changes in the polymer at a molecular level. If so, than these changes may effect the vibrational characteristics of the material, and consequently the Raman spectra produced from the material. Problem Statement: Kevlar composite over-wrapped pressure vessels (COPVs) on the space shuttles are greater than 25 years old. Stress rupture phenomena is not well understood for COPVs. Other COPVs are planned for hydrogen-fueled vehicles using Carbon composite material. Raman spectroscopy is being explored as an non-destructive evaluation (NDE) technique to predict the onset of stress rupture in Kevlar composite materials. Test aged Kevlar strands to discover trends in the Raman response. Strength reduction in Kevlar polymer will manifest itself on the Raman spectra. Conclusions: Raman spectroscopy has shown relative changes in the intensity and FWHM of the ~1613 cm(exp -1) peak. Reduction in relative intensity for creep, fleet leader, and SIM specimens compared to the virgin strands. Increase in FWHM has been observed for the creep and fleet leader specimens compared to the virgin strands. Changes in the Raman spectra may result from redistributing loads within the material due to the disruption of hydrogen bonding between crystallites or defects in the crystallites from aging the Kevlar strands. Peak shifting has not been observed to date. Analysis is ongoing. Stress measurements may provide a tool in the short term.

Washer, Glenn↗

NASA NTRS2005

Hypergolic ignitor

An ignitor for use with the MC-1 rocket engine has a cartridge bounded by two end caps with rupture disc assemblies connected thereto. A piston assembly within the cartridge moves from one end of the cartridge during the ignition process. The inlet of the ignitor communicates with a supply taken from the discharge of the fuel pump. When the pump is initially started, the pressure differential bursts the first rupture disc to begin the movement of the piston assembly toward the discharge end. The pressurization of the cartridge causes the second rupture disc to rupture and hypergolic fluid contained within the cartridge is discharged out the ignitor outlet.

Taylor, Eric S.↗