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The room temperature cyclic stress-strain was determined for D6AC low alloy steel by three different methods. The method that involves the use of a single specimen monotonic tension test after cyclic straining provided the best agreement with the accepted basic method which requires a number of companion specimen tests. The single specimen test is also the simplest to conduct.
Fractography and metallographic sectioning were used to investigate the influence of microstructure and strength on the fracture toughness (KIc) and fracture mechanism of an 18 Ni, 300 grade maraging steel. Increased yield strength from 1442 to 2070 MN/m squared through precipitation hardening results in a KIc loss from 143 to 55 MN/m superscript 3/2. Ti (C,N) Ti2S, and TiC inclusions in sizes from 1 to 8, 1 to 15, and 0.1 to 2 microns respectively serve as sites for void nucleation and lead to fracture by the dimpled rupture process in all strength levels considered. TiC nucleated dimples occupy more than half the fracture in all conditions. Void nucleation rate and resultant number of dimples per unit area of fracture increase with increasing yield strength. Average dimple size decreases with increasing strength and/or overaging which follows from the decreasing amount of stable void growth measured by sectioning tensile specimens. Void growth is assisted by crack branching along a path of TiC inclusions. Coalescence occurs in the highest strength materials by a combination of TiC void nucleation and premature separation at strengthening precipitates.
The elevated-temperature mechanical properties of several ferritic stainless steels were determined. The alloys evaluated included Armco 18SR, GE 1541, and NASA-18T-A. Tensile and creep strength properties at 1073 and 1273 K and residual room temperature tensile properties after creep testing were measured. In addition, 1273 K tensile and creep tests and residual property testing were conducted with Armco 18SR and GE 1541 which were exposed for 200 hours to a severe oxidizing environment in automotive thermal reactors. Aside from the residual tensile properties for Armco 18SR, prior exposure did not affect the mechanical properties of either alloy. The 1273 K creep strength parallel to the sheet-rolling direction was similar for all three alloys. At 1073 K, NASA-18T-A had better creep strength than either Armco 18SR or GE 1541. NASA-18T-A possesses better residual properties after creep testing than either Armco 18SR or Ge 1541.
Radiofrequency sputtering was used to deposit Mo2C, Mo2B5, and MoSi2 coatings on 440C steel substrates. Both sputter etched and preoxidized substrates were used, and the films were deposited with and without a substrate bias of -300 V. The composition of the coatings was measured as a function of depth by X-ray photoelectron spectroscopy combined with argon ion etching. In the interfacial region there was evidence that bias produced a graded interface in Mo2B5 but not in Mo2C. Oxides of iron and of all film constituents except carbon were presented in all cases but the iron oxide concentration was higher and the layer thicker on the preoxidized substrates. The film and iron oxides were mixed in the MoSi2 and Mo2C films but layered in the Mo2B5 film. The presence of mixed oxides correlates with enhanced film adhesion.
Analysis of high temperature low cycle fatigue of AISI 304LC and 316 stainless steels by the method of strainrange partitioning results in four separate strainrange versus life relationships, depending upon the way in which creep-strain and plastic strain are combined within a cycle. Fractography is used in this investigation of the creep-fatigue interaction associated with these cycles. The PP and PC-cycle fractures were transgranular. The PC-cycle resulted in fewer cycles of initiation and shorter total cyclic life for the same applied inelastic strainrange. The CC-cycle had mixed transgranular and intergranular fracture, fewer cycles of initiation and shorter cycle life than PP or PC. The CP-cycle had fully integranular cracking, and failed in fewer cycles than were required for cracks to initate for PP,PC, and CC.
The use of automatic welding for making girth welds in stainless steel tubing was investigated as well as the reduction in fabrication costs resulting from the elimination of radiographic inspection. Test methodology, materials, and techniques are discussed, and data sheets for individual tests are included. Process variables studied include welding amperes, revolutions per minute, and shielding gas flow. Strip chart recordings, as a definitive method of insuring weld quality, are studied. Test results, determined by both radiographic and visual inspection, are presented and indicate that once optimum welding procedures for specific sizes of tubing are established, and the welding machine operations are certified, then the automatic tube welding process produces good quality welds repeatedly, with a high degree of reliability. Revised specifications for welding tubing using the automatic process and weld visual inspection requirements at the Kennedy Space Center are enumerated.
Life tests were conducted at three different loads with three groups of 8.9 cm, pitch diameter spur gears made of vacuum arc remelted AISI 9310 steel. Life was found to vary inversely with load to the 4.3 and 5.1 power at the L-10 and L-50 life levels, respectively. The Weibull slope varied linearly with maximum Hertz contact stress, having an average value of 2.5. The test data when compared to AGMA standards showed a steeper slope for the load-life diagram.
The system identified operates from the primary arc furnace evacuation system as a heat source. Energy from the fume stream is stored as sensible energy in a solid medium (packed bed). A steam-driven turbine is arranged to generate power for peak shaving. A parametric design approach is presented since the overall system design, at optimum payback is strongly dependent upon the nature of the electric pricing structure. The scope of the project was limited to consideration of available technology so that industry-wide application could be achieved by 1985. A search of the literature, coupled with interviews with representatives of major steel producers, served as the means whereby the techniques and technologies indicated for the specific site are extrapolated to the industry as a whole and to the 1985 time frame. The conclusion of the study is that by 1985, a national yearly savings of 1.9 million barrels of oil could be realized through recovery of waste heat from primary arc furnace fume gases on an industry-wide basis. Economic studies indicate that the proposed system has a plant payback time of approximately 5 years.
To determine if the use of automatic welding would allow reduction of the radiographic inspection requirement, and thereby reduce fabrication costs, a series of welding tests were performed. In these tests an automatic welder was used on stainless steel tubing of 1/2, 3/4, and 1/2 inch diameter size. The optimum parameters were investigated to determine how much variation from optimum in machine settings could be tolerate and still result in a good quality weld. The process variables studied were the welding amperes, the revolutions per minute as a function of the circumferential weld travel speed, and the shielding gas flow. The investigation showed that the close control of process variables in conjunction with a thorough visual inspection of welds can be relied upon as an acceptable quality assurance procedure, thus permitting the radiographic inspection to be reduced by a large percentage when using the automatic process.
Friction and wear experiments on 440-C steel surfaces that had been RF-sputtered with titanium carbide when a small percentage of nitrogen was added to the plasma were conducted. X-ray photoelectron spectroscopy and X-ray diffraction were used to analyze the resultant coatings. Results indicate that a small partial pressure of nitrogen (about 0.5%) markedly improves the adherence, friction, and wear properties when compared with coatings applied on sputter-etched oxidized surfaces or in the presence of a small oxygen partial pressure. The improvements are related to the formation of an interface containing a mixture of the nitrides of titanium and iron, which are harder than their corresponding oxides.
Until recently experimental measurements of post-impact temperatures have been obtained only for metals at high pressures. Our aim has been to develop a technique for measuring post-shock temperatures in a variety of materials, including metals and silicates, at pressures in the range of 5 to 50 GPa, providing further insight into the shock process in these substances and additional constraints to available equation of state data. This paper describes the method we have developed, and its application to the determination of post-shock temperatures in aluminum-2024 and stainless steel-304.
Modified process for RF sputtering of titanium carbide coatings onto 440-C steel has resulted in improved adherence. Small partial pressure of nitrogen, approximately 0.5 percent, during first minutes of deposition markedby improved adherence, friction, and wear properties when compared with coatings applied on sputter-etched surfaces, or oxidized surfaces or in presence of small oxygen partial pressure. X-ray photoelectron spectroscopy and X-ray diffraction were used to characterize resultant coatings.
The coefficient of friction was determined for steel skids with and without skegs. The addition of a 1.27 centimeter deep skeg caused the coefficient of friction to increase from an average value of .36 to .53, a 47 percent increase over the flat skid. The addition of a .64 centimeter deep skeg increased the friction coefficient from .36 to .46, a 16 percent increase over the flat skid. Comparisons are made with data for similar test conditions obtained during the X-15 program.
The design and fabrication of wind turbine blades based on 60 foot steel spars are discussed. Performance and blade load information is given and compared to analytical prediction. In addition, performance is compared to that of the original MOD-O aluminum blades. Costs for building the two blades are given, and a projection is made for the cost in mass production. Design improvements to reduce weight and improve fatigue life are suggested.
The time varying effect of nonadiabatic wall conditions on boundary layer properties was studied for a two dimensional wing section and an axisymmetric fuselage. The wing and fuselage sections are representative of the wing root chord and fuselage of a typical transport model for the National Transonic Facility. The analysis was made with a solid wing and three fuselage configurations (one solid and two hollow with varying skin thicknesses) all made from AISI type 310S stainless steel. The displacement thickness and local skin friction were investigated at a station on the model in terms of the time required for these two boundary layer properties to reach an adiabatic wall condition after a 50 K step change in total temperature. The analysis was made for a free stream Mach number of 0.85, a total temperature of 117 K, and stagnation pressures of 2, 6, and 9 atm.
A continuously variable transmission (CVT) design layout was completed. The intended application was for coupling the flywheel to the driveline of a flywheel battery hybrid electric vehicle. The requirements were that the CVT accommodate flywheel speeds from 14,000 to 28,000 rpm and driveline speeds of 850 to 5000 rpm without slipping. Below 850 rpm a slipping clutch was used between the CVT and the driveline. The CVT was required to accommodate 330 ft-lb maximum torque and 100 hp maximum transient. The weighted average power was 22 hp, the maximum allowable full range shift time was 2 seconds and the required lift was 2600 hours. The resulting design utilized two steel V-belts in series to accommodate the required wide speed ratio. The size of the CVT, including the slipping clutch, was 20.6 inches long, 9.8 inches high and 13.8 inches wide. The estimated weight was 155 lb. An overall potential efficiency of 95 percent was projected for the average power condition.
The performance and loading of a large wind rotor, 38.4 m in diameter and composed of two low-cost steel spar blades were examined. Two blades were fabricated at Lewis Research Center and successfully operated on the Mod-0 wind turbine at Plum Brook. The blades were operated on a tower on which the natural bending frequency were altered by placing the tower on a leaf-spring apparatus. It was found that neither blade performance nor loading were affected significantly by this tower softening technique. Rotor performance exceeded prediction while blade loads were found to be in reasonable agreement with those predicted. Seventy-five hours of operation over a five month period resulted in no deterioration in the blade.
The burning behavior of pressed binderless HMX laterally confined in 6.4 mm i.d. steel cases was measured over the pressure range 1.45 to 338 MPa in a constant pressure strand burner. The measured regression rates are compared to those reported previously for unconfined samples. It is shown that lateral confinement results in a several-fold decrease in the regression rate for the coarse particle size HMX above the transition to super fast regression. For class E samples, confinement shifts the transition to super fast regression from low pressure to high pressure. These results are interpreted in terms of the previously proposed progressive deconsolidation mechanism. Preliminary holographic photography and closed bomb tests are also described. Theoretical one dimensional modeling calculations were carried out to predict the expected flame height (particle burn out distance) as a function of particle size and pressure for binderless HMX burning by a progressive deconsolidation mechanism.