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NASA NTRS1999

Particle Segregation in Collisional Shearing Flows

The size segregation of flowing or shaken grains is a commonly observed phenomenon in industrial processes and in nature. In systems that do not involve much agitation of the grains, several mechanisms that involve gravity have been identified as leading to such segregation. In highly agitated flows, there is a mechanism independent of gravity that is available to drive separation of different grains. This is associated with spatial gradients in the energy of their velocity fluctuations. Because collisions between grains inevitably dissipate energy, collisional granular shear flows are usually of limited extent in the direction transverse to the flow. One consequence of this is that shear flows are strongly influenced by their boundaries. Because grains, on average, slip relative to boundaries, a bumpy or frictional boundary can convert slip energy into fluctuation energy. However, because each collision between a grain and the boundary dissipates fluctuation energy, there is a competition between production and dissipation. In principle, it is possible to design the geometry of the boundary - for example, the size and spacing of the bumps - so that the boundary either produces or dissipates fluctuation energy. This permits the control of the component of the spatial gradient of the fluctuation energy that is normal to the boundary. The gradients in fluctuation energy established by such boundaries may be exploited to drive the separation by size or other properties in a binary mixture of spherical grains. Microgravity makes the visual observations possible by permitting us to employ moderate rates of shear. On earth, the effects of gravity can be minimized by shearing so rapidly that the particle pressure overwhelms gravity. However, in this event, separation takes place too rapidly for visual observation, buoyancy and/or condensation associated with the centripetal acceleration must be accounted for, and the particles can be severely damaged. Because, in the absence of gravity, the only available time scale is proportional to the speed of the moving boundary, this speed can be made arbitrarily slow to permit observations and to avoid particle damage, without altering the phenomenon under study. The primary goal of this research is to carry out a physical experiment in which particle segregation is induced and maintained in a collisional flow of a binary mixture of two different types of spheres.

Jenkins, J. T.↗

NASA NTRS1987

Defects in nickel-base superalloys

The presence of substantial amounts of the sigma phase in Ni-base superalloys can drastically reduce the alloy's stress rupture life. No predictive system exists which is entirely successful in anticipating the formation of sigma, mu, and similar phases in new and substantially different alloys. Freckles are defects due to the segregation of elements in quantities that can lead to phase precipitation, and are caused by gravity-driven fluid motion that yields microsegregation in the ingots typically used in the fabrication of structures based on these alloys. Also noted are the effects of porosity and grain boundaries on superalloy mechanical properties.

Dreshfield, Robert L.↗

NASA NTRS1994

Oxidation of Palladium-Chromium Alloys for High Temperature Applications

An alloy consisting of Pd with 13 wt % Cr is a promising material for high temperature applications. High temperature performance is degraded by the oxidation of the material, which is more severe in the fine wires and thin films used for sensor applications than in the bulk. The present study was undertaken to improve our understanding of the physical and chemical changes occurring at these temperatures and to identify approaches to limit oxidation of the alloy. The alloy was studied in both ribbon and wire forms. Ribbon samples were chosen to examine the role of grain boundaries in the oxidation process because of the convenience of handling for the oxidation studies. Wire samples 25 microns in diameter which are used in resistance strain gages were studied to correlate chemical properties with observed electrical, physical, and structural properties. Overcoating the material with a metallic Cr film did prevent the segregation of Pd to the surface; however, it did not eliminate the oxidation of the alloy.

Piltch, Nancy D.↗

NASA NTRS2006

Metallurgical Design and Development of NASA Crawler/Transporter Tread Belt Shoe Castings

The NASA Crawler/Transporters (CT-1 and CT-2) used to transport the Space Shuffles are one of the largest tracked vehicles in existence today. Two of these machines have been used to move space flight vehicles at Kennedy Space Center since the Apollo missions of the 1960's and relatively few modifications have been made to keep them operational. In September of 2003 during normal Crawler/Transporter operations cracks were observed along the roller pad surfaces of several tread belt shoes. Further examination showed 20 cracked shoes on CT-1 and 40 cracked shoes on CT-2 and a formal failure analysis investigation was undertaken while the cracked shoes were replaced. Six shoes were cross-sectioned with the fracture surfaces exposed and it was determined that the cracks were due to fatigue that initiated on the internal casting web channels at pre-existing casting defects and propagated through thickness both transgranularly and intergranularly between internal shrinkage cavities, porosity, and along austenitic and ferritic grain boundaries. The original shoes were cast during the 1960's using a modified 861330 steel with slightly higher levels of chromium, nickel and molybdenum followed by heat treatment to achieve a minimum tensile strength of 11 Oksi. Subsequent metallurgical analysis of the tread belt shoes after multiple failures showed excessive internal defects, alloy segregation, a nonuniform ferritic/ bainitic/martensitic microstructure, and low average tensile properties indicative of poor casting and poor heat-treatment. As a result, NASA funded an initiative to replace all of the tread belt shoes on both crawler/transporters along with a redesign of the alloy, manufacturing, and heat-treatment to create a homogeneous cast structure with uniform mechanical and metallurgical properties. ME Global, a wholly owned subsidiary of ME Elecmetal based in Minneapolis, MN was selected as manufacturing and design partner to develop the new shoes and this paper describes the research, development, and manufacturing that resulted in the successful delivery of 1044 new Crawler/Transporter tread belt shoes all meeting rigid metallurgical and mechanical design criteria derived from finite element modeling of the stress loads required for safe space shuttle transport.

Parker, Donald S.↗

NASA NTRS1978

Fractographic analysis of gaseous hydrogen induced cracking in 18Ni maraging steel

Electron microscope fractographic analysis supplemented an extensive study of the kinetics of gaseous hydrogen assisted cracking in 18Ni maraging steel. Temperature determined the crack path morphology in each steel which, in turn, was directly related to the temperature dependence of the crack growth rate. Crack growth in the low temperature regime proceeded along prior austenite grain boundaries. Increasing the temperature above a critical value produced a continuously increasing proportion of transgranular quasi-cleavage associated with lath martensite boundaries. The amount of transgranular cracking was qualitatively correlated with the degree of temperature-induced deviation from Arrhenius behavior. Fractographic observations are interpreted in terms of hypothesized mechanisms for gaseous hydrogen embrittlement. It is concluded that hydrogen segregation to prior austenite and lath martensite boundaries must be considered as a significant factor in developing mechanisms for gaseous embrittlement of high strength steels.

Gangloff, R. P.↗

NASA NTRS2016

Microstructural and Creep Properties of Boron- and Zirconium-Containing Cobalt-Based Superalloys

The effects of micro-additions of boron and zirconium on grain-boundary (GB) structure and strength inpolycrystalline γ(f.c.c.) plus γ’(L12) strengthened Co-9.5Al-7.5W-X at. % alloys (X=0-Ternary, 0.05B, 0.01B,0.05Zr, and 0.005B-0.05Zr at. %) are studied. Creep tests performed at 850 °C demonstrate that GB strength and cohesion limit the creep resistance and ductility of the ternary B- and Zr-free alloy due to intergranular fracture. Alloys with 0.05B and 0.005B-0.05Zr both exhibit improved creep strength due to enhanced GB cohesion,compared to the baseline ternary Co-9.5Al-7.5W alloy, but alloys containing 0.01B or 0.05Zr additions displayed no benefit. Atom-probe tomography (APT) is utilized to measure GB segregation, where B and Zr are demonstrated to segregate at GBs. A Gibbsian interfacial excess of 5.57 ± 1.04 atoms nm(exp) -2 was found for B at aGB in the 0.01B alloy and 2.88 ± 0.81 and 2.40 ± 0.84 atoms nm2 for B and Zr, respectively, for the 0.005B-0.05Zr alloy. The GBs in the highest B-containing (0.05B) alloy exhibit micrometer-sized boride precipitates with adjacent precipitate denuded-zones (PDZs), whereas secondary precipitation at the GBs is absent in theother four alloys. The 0.05B alloy has the smallest room temperature yield strength, by 6%, which is attributedto the PDZs, but it exhibits the largest increase in creep strength (with an ~2.5 order of magnitude decrease inthe minimum strain rate for a given stress at 850 °C) over the baseline Co-9.5Al-7.5W alloy.

Creep↗

NASA NTRS1992

Pressure regimes and core formation in the accreting earth

Recent work suggests that a large degree of melting is required to segregate metal from silicates, suggesting a connection with the formation of magma oceans. At low pressures metallic liquids do not wet silicate minerals, preventing the metal from aggregating into large masses that can sink. At high pressures, above 25 GPa, the dihedral angles of grains in contact with oxygen-rich metallic liquids may be reduced enough to allow percolation of metal, but this has not been confirmed. Physical models of core formation and accretion may therefore involve the formation of magma oceans and the segregation of metal at both high and low pressures. Models of core formation involving different pressure regimes are discussed as well as chemical evidence bearing on the models. Available geophysical data is ambiguous. The nature of the 670 km boundary (chemical difference or strictly phase change) between the upper and lower mantle is in doubt. There is some evidence that plumes are derived from the lower mantle, and seismic tomography strongly indicates that penetration of subducting oceanic crust into the lower mantle, but the tomography data also indicates that the 670 km discontinuity is a significant barrier to general mantle convection. The presence of the D' layer at the base of the lower mantle could be a reaction zone between the mantle and core indicating core-mantle disequilibrium, or D' layer could be subducted material. The abundance of the siderophile elements in the mantle could provide clues to the importance of high pressure processes in Earth, but partition coefficients at high pressures are only beginning to be measured.

Newsom, H. E.↗

NASA NTRS2003

Sheet Flows, Avalanches, and Dune Evolution on Earth and Mars

This investigation is a collaboration between researchers at Cornell University, the University of Florida, and the University of Rennes 1, France. Flow modeling at Cornell University focused on mechanisms for the suspension and transport of wind-blown sand that are important in both terrestrial and Martian environments. These mechanisms include the saltation (or jumping) of grains, collisions between grains, and the interaction of grains with the velocity fluctuations of the turbulent wind. Of particular interest are sheet flows; these are relatively thin, highly concentrated regions of grains flowing near the ground under the influence of a strong turbulent wind. In them, the grains are suspended by interparticle collisions. Sheet flows may be relatively rare events, but they have the capacity to move great amounts of sand. In order to describe sheet flows, a turbulent mixture theory was formulated for particles in a fluid in which fluctuations in the volume fiaction of the particles take place on the scale of the turbulent eddies. Ensemble averaged equations for particle and fluid mass, momentum, and energy and fluid rate of dissipation were expressed in terms of Farve (concentration) averaged velocities and the associated velocity fluctuations. Correlations that describe the turbulent suspension of particles and dissipation of turbulent energy of both phases due to fluid particle interactions were modeled and boundary conditions at the bed and at the upper surface of the collisional flow were formulated. The boundary conditions at the upper surface were tested in a numerical simulation developed at the University of Florida. Steady and unsteady solutions for steady and unsteady fully-developed flows were obtained over a range of wind speeds fiom the lowest for which collisional between particles occurred to at which turbulent suspension is found to dominate collisional suspension. Below the value of the wind speed at which collisions between particles were unimportant, numerical solutions were obtained for the velocity distribution function and the resulting fields of concentration, particle and gas mean velocity, and particle shear stress for the steady two-dimensional saltation of spherical sand particles driven by a turbulent wind over a bed characterized by a simple relationship (the splash function) between the properties of incoming particles and those of the rebounding particles and other particles ejected fiom the bed. At the University of Rennes 1, experiments devoted to the characterization of the splash function for beds consisting of either random or ordered arrays of spheres in two- dimensions were completed. These indicated the role played by the packing geometry in the rebound and ejection of grains. Preliminary experiments on response of a three- dimensional collision bed to a collision with a single particle were performed. Data was taken with a single camera focused on the plane of collision. Here, for example, the decrease of the effective coefficient of restitution of the bed with an increase of the angle of incidence of the incoming particle has been measured. Other experiments on avalanches at Rennes studied the properties of the flows of particles that are responsible for the motion of the leeward side of a dune. In these, the dependence of the initiation of avalanches on the packing and depth of the particles was measured. Particle migration was studied in inclined flows of a binary mixture of disks and the mechanisms of diffision and segregation were isolated and characterized. The influence of side wall on dense, rapid inclined flows was measured and shown to be the reason why the angle of the free surface in such flows can exceed the static angle of repose. Future research will be devoted to a better understanding the transition between saltating (collisionless) and collisional flows as the wind speed the increases. This will involve the understanding of the evolution of the splash function as clisions with the bed become more numerous, more frequent, and more violent.

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