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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Ultrasonic Spectroscopy of Stainless Steel Sandwich Panels

Enhanced, lightweight material systems, such as 17-4PH stainless steel sandwich panels are being developed for use as fan blades and fan containment material systems for next generation engines. In order to improve the production for these systems, nondestructive evaluation (NDE) techniques, such as ultrasonic spectroscopy, are being utilized to evaluate the brazing quality between the 17-4PH stainless steel face plates and the 17-4PH stainless steel foam core. Based on NDE data, shear tests are performed on sections representing various levels of brazing quality from an initial batch of these sandwich structures. Metallographic characterization of brazing is done to corroborate NDE findings and the observed shear failure mechanisms.

Cosgriff, Laura M.↗
NASA NTRS1993

Fracture-tough, high hardness stainless steel and method of making same

A cryogenically-formed and tempered stainless steel is provided having improved fracture toughness and corrosion resistance at a given hardness level, such as, for example, of at least about Rc 60 for bearing applications. The steel consists essentially of, in weight %, about 21 to about 24% Co, about 11 to about 13% Cr, about 7 to about 9% Ni, about 0.1 to about 0.5% Mo, about 0.2 to about 0.3% V, about 0.28 to about 0.32% C, and the balance iron. The steel includes a cryogenically-formed martensitic microstructure tempered to include about 5 to about 10 volume % post-deformation retained austenite dispersed therein and M.sub.2 C-type carbides, where M is Cr, Mo, V, and/or Fe, dispersed in the microstructure.

Olson, Gregory B.↗
NASA NTRS2009

A Stainless-Steel Mandrel for Slumping Glass X-ray Mirrors

We have fabricated a precision full-cylinder stainless-steel mandrel at Marshall Space Flight Center. The mandrel is figured for a 30-cm diameter primary (paraboloid) mirror of an 840-cm focal-length Wolter-1 telescope. We have developed this mandrel for experiments in slumping.thermal forming at about 600 C.of glass mirror segments at Goddard Space Flight Center, in support of NASA's participation in the International X-ray Observatory (IXO). Precision turning of stainless-steel mandrels may offer a low-cost alternative to conventional figuring of fused-silica or other glassy forming mandrels. We report on the fabrication, metrology, and performance of this first mandrel; then we discuss plans and goals for stainless-steel mandrel technology.

Gubarev, Mikhail V.↗
NASA NTRS2008

A Stainless-Steel Mandrel for Slumping Glass X-Ray Mirrors

We have fabricated a precision full -cylinder stainless-steel mandrel at Marshall Space Flight Center. The mandrel is figured for a 30-cm-diameter primary (paraboloid) mirror of an 840-cm focal-lengthWolter-1 telescope. We have developed this mandrel for experiments in slumping.thermal forming at about 600 C-of glass mirror segments at Goddard Space Flight Center, in support of NASA fs participation in the International X -ray Observatory (IXO). Precision turning of stainless ]steel mandrels may offer a lowcost alternative to conventional figuring of fused -silica or other glassy forming mandrels. We report on the fabrication, metrology, and performance of this first mandrel; then we discuss plans and goals for stainless-steel mandrel technology.

ODell, Stephen L.↗
NASA NTRS2010

Particle Impact Ignition Test Data on a Stainless Steel Hand Valve

This slide presentation reviews the particle impact ignition test of a stainless steel hand valve. The impact of particles is a real fire hazard with stainless steel hand valves, however 100 mg of particulate can be tolerated. Since it is unlikely that 100 mg of stainless steel contaminant particles can be simultaneously released into this type of valve in the WSTF configuration, this is acceptable and within statistical confidence as demonstrated by testing.

Peralta, Stephen↗
NASA NTRS2011

Characterization of Electron Beam Free-Form Fabricated 2219 Aluminum and 316 Stainless Steel

Researchers at NASA Langley Research Center have developed an additive manufacturing technology for ground and future space based applications. The electron beam free form fabrication (EBF3) is a rapid metal fabrication process that utilizes an electron beam gun in a vacuum environment to replicate a CAD drawing of a part. The electron beam gun creates a molten pool on a metal substrate, and translates with respect to the substrate to deposit metal in designated regions through a layer additive process. Prior to demonstration and certification of a final EBF3 part for space flight, it is imperative to conduct a series of materials validation and verification tests on the ground in order to evaluate mechanical and microstructural properties of the EBF3 manufactured parts. Part geometries of EBF3 2219 aluminum and 316 stainless steel specimens were metallographically inspected, and tested for strength, fatigue crack growth, and fracture toughness. Upon comparing the results to conventionally welded material, 2219 aluminum in the as fabricated condition demonstrated a 30% and 16% decrease in fracture toughness and ductility, respectively. The strength properties of the 316 stainless steel material in the as deposited condition were comparable to annealed stainless steel alloys. Future fatigue crack growth tests will integrate various stress ranges and maximum to minimum stress ratios needed to fully characterize EBF3 manufactured specimens.

Ekrami, Yasamin↗
NASA NTRS2007

Joint Test Report for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel

Headquarters National Aeronautics and Space Administration (NASA) chartered the NASA Acquisition Pollution Prevention (AP2) Office to coordinate agency activities affecting pollution prevention issues identified during system and component acquisition and sustainment processes. The primary objectives of the AP2 Office are to: (1) Reduce or eliminate the use of hazardous materials or hazardous processes at manufacturing, remanufacturing, and sustainment locations. (2) Avoid duplication of effort in actions required to reduce or eliminate hazardous materials through joint center cooperation and technology sharing. The objective of this project was to qualify candidate alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel applications at NASA facilities. This project compares the surface preparation/depainting performance of the proposed alternatives to existing surface preparation/depainting systems or standards. This Joint Test Report (JTR) contains the results of testing as per the outlines of the Joint Test Protocol (JTP), Joint Test Protocol for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel, and the Field Test Plan (FTP), Field Evaluations Test Plan for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel, for critical requirements and tests necessary to qualify alternatives for coating removal systems. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of government and industry participants. This JTR documents the results of the testing as well as any test modifications made during the execution of the project. This JTR is made available as a reference for future pollution prevention endeavors by other NASA Centers, the Department of Defense and commercial users to minimize duplication of effort. The current coating removal processes identified herein are for polyurethane, epoxy and other paint systems applied by conventional wet-spray processes. A table summarizes the target hazardous materials, processes and materials, applications, affected programs, and candidate substrates.

Lewis, Pattie↗
NASA NTRS2004

Corrosion Performance of Stainless Steels in a Simulated Launch Environment

At the Kennedy Space Center, NASA relies on stainless steel (SS) tubing to supply the gases and fluids required to launch the Space Shuttle. 300 series SS tubing has been used for decades but the highly corrosive environment at the launch pad has proven to be detrimental to these alloys. An upgrade with higher alloy content materials has become necessary in order to provide a safer and long lasting launch facility. In the effort to find the most suitable material to replace the existing AISI 304L SS ([iNS S30403) and AISI 316L SS (UNS S31603) shuttle tubing, a study involving atmospheric exposure at the corrosion test site near the launch pads and electrochemical measurements is being conducted. This paper presents the results of an investigation in which stainless steels of the 300 series, 304L, 316L, and AISI 317L SS (UNS S31703) as well as highly alloyed stainless steels 254-SMO (UNS S32154), AL-6XN (N08367) and AL29-4C ([iNS S44735) were evaluated using direct current (DC) electrochemical techniques under conditions designed to simulate those found at the Space Shuttle Launch pad. The electrochemical results were compared to the atmospheric exposure data and evaluated for their ability to predict the long-term corrosion performance of the alloys.

Calle, Luz Marina↗
NASA NTRS2013

Determine ISS Soyuz Orbital Module Ballistic Limits for Steel Projectiles Hypervelocity Impact Testing

A new orbital debris environment model (ORDEM 3.0) defines the density distribution of the debris environment in terms of the fraction of debris that are low-density (plastic), medium-density (aluminum) or high-density (steel) particles. This hypervelocity impact (HVI) program focused on assessing ballistic limits (BLs) for steel projectiles impacting the enhanced Soyuz Orbital Module (OM) micrometeoroid and orbital debris (MMOD) shield configuration. The ballistic limit was defined as the projectile size on the threshold of failure of the OM pressure shell as a function of impact speeds and angle. The enhanced OM shield configuration was first introduced with Soyuz 30S (launched in May 2012) to improve the MMOD protection of Soyuz vehicles docked to the International Space Station (ISS). This test program provides HVI data on U.S. materials similar in composition and density to the Russian materials for the enhanced Soyuz OM shield configuration of the vehicle. Data from this test program was used to update ballistic limit equations used in Soyuz OM penetration risk assessments. The objective of this hypervelocity impact test program was to determine the ballistic limit particle size for 440C stainless steel spherical projectiles on the Soyuz OM shielding at several impact conditions (velocity and angle combinations). This test report was prepared by NASA-JSC/ HVIT, upon completion of tests.

Lyons, Frankel↗
DOE OSTI2021

Compatibility of Steels in Supercritical CO2 at 450°-650°C

Supercritical CO2 (sCO2) power cycles, particularly direct-fired cycles, have the possibility of revolutionizing clean fossil energy. However, in the lower temperature sections of the cycle, lower cost steels are needed in order to lower the cost of the sCO2 technology. Representative 9 and 12%Cr steels and conventional and advanced austenitic steels are being evaluated at 450-650°C using mass change, bulk carbon (C) content and room temperature tensile properties to determine the maximum use temperatures for both direct- and indirect-fired sCO2 cycles. After 1000 h exposures in research grade (RG) sCO2 at 300 bar and RG sCO2 with 1% O2 and 0.1% H2O additions, the results suggest that increasing the Cr content from 9 to 12% yielded no signficant benefit under these conditions but the higher Cr and Ni contents in S31025 provided better compatibility in RG sCO2 at 650°C but limited benefit at 550°C with impurities. For S31609, the formation of Fe-rich oxide after exposure to RG sCO2 at 650°C resulted in both an increase in the bulk C content and a large drop in room temperature ductility. The evidence suggests thin, protective oxides prevented C ingress in these conditions.

Pint, Bruce↗
DOE OSTI2021

Corrosion Behavior of Alloy Structural Steels in Catechol and Biomass-Derived Pyrolysis Oils

Electrochemical impedance spectroscopy (EIS) was used to assess the corrosion behavior of three steels, 2.25Cr-1Mo, 5Cr-1Mo and 9Cr-1Mo (UNS K21590, S50200 and K90941) in bio-oils and catechol, an organic constituent commonly found in bio-oils. Two types of biomass pyrolysis oils produced from selected forest residue feedstocks, classified as high-ash and high-moisture (HAHM) and low-ash and low-moisture (LALM) types and 10 wt.% catechol, were used to test the alloys. According to previous results, 10 wt.% catechol in a water and methanol mixture was corrosive to 2.25Cr-1Mo but not to 9Cr-1Mo, highlighting that increasing Cr content in the steels resulted in improved corrosion resistance. 5Cr-1Mo, a steel with an intermediate Cr content, was tested in catechol solutions to better estimate the critical value of Cr for corrosion resistance under these conditions. Also, the three alloys were tested in both HAHM and LALM bio-oils to assess corrosion susceptibility. For EIS measurements, a customized electrochemical setup was employed to minimize the ohmic path through the bio-oils. The corrosion susceptibility was evaluated by determining the resistance at the alloy-corrosive medium interface.

Jun, Jiheon↗
DOE OSTI2022

Corrosion of Stainless and Carbon Steel in Aqueous Piperazine for CO2 Capture

Current obstacles that prevent commercial implementation of amine-scrubbing CO2 capture are the high costs. Reducing capital costs by appropriate selection of construction materials, which requires knowledge of material corrosion performance for the process, will improve the economic feasibility of this technology. Corrosion was evaluated in three pilot plant campaigns using aqueous piperazine with the Advanced Stripper (PZAS). 316L stainless steel (SS) experienced higher corrosion than 304 SS and 2205 duplex SS, and the corrosion rate showed strong dependence on the temperature. 304 and 2205 performed well at all locations and should be good construction materials for PZAS. Degraded PZ exacerbated 316L corrosion, and removal of PZ degradation products using a carbon adsorption bed significantly reduced corrosion. Carbon steel (CS) corrosion showed a weak temperature effect because the corrosion was more dependent on the protective siderite film. The protectiveness of the films was related to fluid velocity. Ni-based alloys corroded in PZ, and the rate increased with temperature. Corrosion of C1010 CS and SS (304, 316L, 430) was measured at absorber and water wash conditions on the bench-scale. Corrosion rate decreases with increasing PZ. 8 With more than 0.003 m PZ in solution, CS has acceptable corrosion performance. Corrosion of CS increases with increasing partial pressure of CO2, suggesting loading is another dominant parameter for carbon steel corrosion. Temperature has a less significant effect than PZ concentration and loading. CS corrosion increases with increasing flow velocity at both absorber and water wash conditions. SS had little corrosion at this lower temperature. Performance of siderite (FeCO3) protective films on CS was studied at representative stripper conditions on the bench-scale. Siderite films can deposit on the surface of CS in CO2-loaded PZ solution at temperatures >100 °C and protect CS from corrosion. The protection may fail in degraded PZ. Ethylenediamine (EDA) is one of the major contributors for the loss of film protectiveness or can be the surrogate for the effect of PZ degradation on siderite film protection. A link between protectiveness and the apparent density of siderite films was discovered. The apparent density of siderite films decreases with increasing flow velocity and decreasing CO2 loading, resulting in higher corrosion of CS.

Liu, Ching-Ting↗
DOE OSTI2024

System and method of making a cast steel alloy crankshaft having low porosity

Systems and methods of making a cast steel alloy crankshaft for an internal combustion engine are provided. The method comprises providing a mold of the crankshaft. The mold has cavities to form the crankshaft. The method further comprises melting a first metallic material at between 1400 degrees Celsius (° C.) and 1600° C. to define a molten metallic material. In addition, the method further comprises feeding the molten metallic material at a riser connection angle of between 30° and 75° in the cavities of the negative sand cast mold. The method further comprises cooling the molten metallic material at a solidification time of between 5 seconds (sec) and 20 sec in the negative sand cast mold with at least one chill member to define a solidified metallic material having dimensions of the cast steel alloy crankshaft. Furthermore, the method comprises separating the solidified metallic material from the negative sand cast mold to define the cast steel alloy crankshaft.

Wang, Liang↗
DOE OSTI2022

Effects of chemical segregation on ductility-anisotropy in high strength Fe-Mn-Al-C lightweight austenitic steels

Ductile Fe-Mn-Al-C lightweight steels offer great potential as high specific strength materials for weight critical applications. In the present work, very high yield (~1 GPa) and ultimate tensile strength levels (~1.5 GPa) were obtained along the rolling and transverse directions of Fe-30Mn-8.5Al-0.9Si-0.9C-0.5Mo (wt.%), with high tensile elongation to failure of ~35%. This excellent mechanical behavior was attributed to the nanoscale, ordered κ-carbide precipitates formed during aging after rolling. However, tensile ductility was not isotropic through all directions of the rolled plate. In particular, the ductility was consistently lower than 5% true strain along the normal direction. Upon detailed microstructural investigations, micro-scale lamellar chemical micro-segregation bands were detected, which caused the observed anisotropic embrittlement along certain plate directions. These bands resulted in low failure strains along the normal direction since it is oriented perpendicular to these chemical segregation bands, resulting in a failure type reminiscent of delamination-induced cleavage fracture. Chemical segregation causes an inhomogeneous κ-carbide precipitate distribution upon aging, producing more pronounced mechanical anisotropy after peak-aging as compared to the solution heat treated samples. Surprisingly, deformation twinning was observed after tensile deformation of solution-heat treated specimens via electron-backscatter diffraction experiments, which is anomalous for a high stacking faulty energy (SFE) material. Further, it was proposed that chemical micro-segregation promotes locally different SFE regions, leading to deformation twinning in this nominally high SFE material. Overall, this work demonstrates the effects of chemical segregation on mechanical properties and microstructural evolution in a high performance, lightweight Fe-Mn-Al-C steel.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

The need to consider regional supply chains and water usage in H 2 –steel transition

The iron and steel industry is one of the largest contributors to U.S. and global greenhouse gas emissions. Hydrogen can act as a promising reducing agent and clean energy carrier to decarbonize this sector, and has received significant attention in terms of process modelling, techno-economic analysis, and life cycle assessment in recent years. Policy incentives, hydrogen storage and transportation, and water stress levels are key factors that require significantly more consideration in order to realize hydrogen’s potential to decarbonize this industry. This review demonstrates the need for a systematic understanding and critical assessment of these areas, and their profound impacts on the decarbonization of the iron and steel sector. Furthermore, hydrogen and water supply face competition from other hard-to-decarbonize sectors, which should be considered on national and regional levels. Lastly, future research should also consider the impact of other environmental factors and hydrogen leak when deploying hydrogen at scale for industrial decarbonization.

Green steel↗
DOE OSTI2022

Tempering kinetics during multilayer laser additive manufacturing of a ferritic steel

Grade 91 steel forms martensite during additive manufacturing and the extent of tempering of martensite significantly affects the mechanical properties of parts. Currently, there is a lack of quantitative understanding of the tempering kinetics for Grade 91 steel, and as a result, the effects of repeated thermal cycles on properties for different processing conditions cannot be determined. Here we evaluate the tempering kinetics by determining the constant terms in the Johnson Mehl Avrami kinetic equation from the tempering data available in the literature and the thermal cycles computed using a rigorously-tested heat and fluid flow model of multi-layer additive manufacturing. The raw tempering data are cleaned using a neural network to enhance accuracy. The lower layers experience repeating cycles of heating and cooling when the upper layers are added. As a result, the hardness is reduced owing to the tempering of martensite. In contrast, martensite formed in the upper layers is not tempered to the same extent and the hardness remains high. Therefore, the hardness of the part increases with the distance from the substrate. Variations in the heat input at different laser powers and scanning speeds significantly affect the extent of tempering. Finally, since the method used here can provide a quantitative understanding of the tempering of martensite and the spatial variation in hardness, it can be used to tailor the microstructure and hardness of heat treatable printed metallic parts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

The study investigated how post‐weld heat treatment (PWHT) temperature affects the microstructure and localized deformation/fracture during bend testing of rotary inertia friction welds (RIFW) between AISI 422 stainless steel and AISI 4140 steel. RIFW produced a fully martensitic interface with approximately 550 HV hardness in both the thermo-mechanically affected (TMAZ) and heat‐affected zones (HAZ). Due to differences in temper resistance, the 4140 TMAZ/HAZ softened progressively under PWHT temperatures from 525 °C to 700 °C, while the 422 TMAZ unexpectedly maintained about 550 HV up to 600 °C before significantly softening at temperatures ≥625 °C. This asymmetric softening generated steep hardness gradients across the interface at temperatures ≤600 °C. Furthermore, carbon migration across the interface was minimal up to 600 °C, moderate at 625 °C, and by 700 °C produced a carbide‐rich eutectoid layer in the 422 TMAZ alongside a carbon‐depleted soft ferrite layer in the 4140 TMAZ. Strain during bending was PWHT‐dependent, concentrating on the 4140 side; in as-welded joints, the high hardness led to deformation and crack initiation in the base metals, whereas in PWHT samples, cracking initiated in the softened 4140 TMAZ near the interface. The intermediate PWHT temperature of 625 °C offered the best balance of limited carbon diffusion across the interface, relatively low peak weld hardness and minimized hardness gradients across the interface, more homogenous deformation, and good bend test performance.

4140 low-alloy steel↗
DOE OSTI2022

Radiation induced amorphization of carbides in additively manufactured and conventional ferritic-martensitic steels: In-situ experiments on extraction replicas

In-situ irradiations using 1 MeV Kr 2+ ions in a transmission electron microscope were performed on extraction replica samples containing M 23 C 6 carbides and MX carbonitrides from two ferritic-martensitic (FM) steels: (i) 9%Cr-1%W-TaV based Eurofer97 and (ii) 9%Cr-1%Mo-VNb (all in wt.%) based additively manufactured (AM) Grade91 steel. The irradiations were performed between 100 and 773 K up to a maximum dose of ~2.4 displacements per atom (dpa). The M 23 C 6 carbides are highly susceptible to radiation induced amorphization (RIA), while the MX type nanoprecipitates are highly amorphization resistant across the entire irradiation temperature range. Between 100 and 423 K, RIA of M 23 C 6 carbides occurs very rapidly with critical amorphization doses ranging between ~0.35 and 0.9 dpa, increasing to higher doses at 573 K. Complete amorphization of the M 23 C 6 carbides up to doses of ~2.4 dpa is not possible at 773 K under the present irradiation conditions. The critical amorphization dose of M 23 C 6 carbides increases nearly exponentially with irradiation temperature. The critical temperature for the crystalline-to-amorphous phase transformation (T c→a ) of M 23 C 6 carbides irradiated as replica samples, i.e. without the surrounding metal matrix, was estimated to be ~812 K. Comparing the present results with neutron irradiation data on bulk samples reveals a decrease in the critical amorphization dose for M 23 C 6 and an increase of T c→a , highlighting the effect of dose rate on the amorphization behavior that is qualitatively consistent with literature on other non-metals. Changes in the minor chemistry of M 23 C 6 , such as presence or absence of W, V, Nb, Mo, seems to have little effect on the amorphization behavior. Here, in-situ irradiations on extraction replica samples provide a novel pathway to explore radiation tolerance of nanoprecipitates in nuclear structural materials

36 MATERIALS SCIENCE↗