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Molybdenum is substituted for tungsten on an atomic basis in a cobalt-based alloy, S-1, thus enabling the alloy to be formed into various mill products, such as tubing and steels. The alloy is weldable, has good high temperature strength and is not subject to embrittlement produced by high temperature aging.
The strength retention of ceramic materials during extended high-temperature cyclic exposure is critical to their widespread application in gas turbine engines. During a continuing NASA funded program initated in 1979, reaction bonded silicon nitride (RBSN), sintered silicon carbide (SSC), reaction sintered silicon carbide (RSSC), and sintered silicon nitride (SSN) materials were evaluated following simulated gas turbine engine exposures. Exposures were performed by cycling specimens five times per hour between a high velocity burner discharge and a rapid air quench. The retained flexural strengths were determined following up to 3500 hours of exposure at temperatures up to 1370 C. Post-exposure strengths have been correlated with fractography and surface examination using SEM. Results illustrate excellent strength retention of SSC materials after 3500 hours of exposure to 1370 C. At 1200 C, RBSN and RSSC also demonstrate significant strength retention. Although SSN materials typically suffer significant strength losses during exposures at 1200 C, a new composition, which has improved high-temperature strength, also shows improved durability. In the majority of the materials, strength loss is typically associated with flaw formation in the protective SiO2 layer.
Strength and high-temperature stability of dispersion strengthened nickel-magnesium oxide alloys
Inconel 617 is a nickel-based superalloy which is being considered for heat-shield applications because of its high-temperature strength, good oxidation resistance and high emittance of oxidized surfaces. While the effects of simulated reentry conditions on emittance and oxidation of Inconel 617 have been studied, the combined effects of the ground-based environment with sea salt exposure and the reentry environment have not been evaluated. Experimental results are presented to show the effects of environmental simulation including ground-based and reentry exposure on the emittance and oxidation of Inconel 617. Specimens were exposed to simulated reentry at a surface temperature of 2000 F in the Langley Research Center Hypersonic Materials Environmental Test System (HYMETS) Facility with and without alternate exposures to an atmospheric seashore environment or a laboratory sea salt environment. This paper presents emittance, mass loss, oxide chemistry, and alloy composition data for the specimens.
Inconel 617 is a nickel-based superalloy which is being considered for heat-shield applications because of its high-temperature strength, good oxidation resistance and high emittance of oxidized surfaces. While the effects of simulated reentry conditions on emittance and oxidation of Inconel 617 have been studied, the combined effects of the ground-based environment with sea salt exposure and the reentry environment have not been evaluated. Experimental results are presented to show the effects of environmental simulation including ground-based and reentry exposure on the emittance and oxidation of Inconel 617. Specimens were exposed to simulated reentry at a surface temperature of 2000 F in the Langley Research Center Hypersonic Materials Environmental Test System (HYMETS) Facility with and without alternate exposures to an atmospheric seashore environment or a laboratory sea salt environment. This paper presents emittance, mass loss, oxide chemistry, and alloy composition data for the specimens.
The mechanical properties of NASA Lewis developed SiC/RBSN composites and their thermal and environmental stability havd been studied. The composites consist of nearly 30 vol pct of aligned 142 micron diameter chemically vapor-deposited SiC fibers in a relatively porous silicon nitride matrix. In the as-fabricated condition, the unidirectional and 2-D composites exhibited metal-like stress-strain behavior, graceful failure, and showed improved properties when compared with unreinforced matrix of comparable density. Furthermore, the measured room temperature tensile properties were relativley independent of tested volume and were unaffected by artifical notches normal to the loading direction or by thermal shocking from temperatures up to 800 C. The four-point bend strength data measured as a function of temperature to 1400 C in air showed that as-fabricated strength was maintained to 1200 C. At 1400 C, however, nearly 15 pct loss in strength was observed. Measurement of room temperature tensile strength after 100 hr exposure at temperatures to 1400 C in a nitrogen environment indicated no loss from the as-fabricated composite strength. On the other hand, after 100 hr exposure in flowing oxygen at 1200 and 1400 C, the composites showed approximately 40 pct loss from their as-fabricated ultimate tensile strength. Those exposed between 400 to 1200 C showed nearly 60 pct strength loss. Oxidation of the fiber/matrix interface as well as internal oxidation of the porous Si3N4 matrix are likely mechanisms for strength degradation. The excellent strength reproducibility, notch insensitivity, and high temperature strength of the composite makes it an ideal candidate for advanced heat engine applications provided coating or densification methods are developed to avoid internal oxidation attack.
A study of molybdenum and three dilute molybdenum-rhenium alloys was undertaken to determine the effects of rhenium on the low temperature ductility and other mechanical properties of molybdenum. Alloys containing 3.9, 5.9, and 7.7 atomic percent rhenium exhibited lower ductile-brittle transition temperatures than did the unalloyed molybdenum. The maximum improvement in the annealed condition was observed for molybdenum - 7.7 rhenium, which had a ductile-brittle transition temperature approximately 200 C (360 F) lower than that for unalloyed molybdenum. Rhenium additions also increased the low and high temperature tensile strengths and the high temperature creep strength of molybdenum. The mechanical behavior of dilute molybdenum-rhenium alloys is similar to that observed for dilute tungsten-rhenium alloys.
Oxide eutectics offer high-temperature strength retention and creep resistance in oxidizing environments. Al2O3-ZrO2 eutectic strengths have been studied since the 1970's. Directionally solidified oxide eutectics exhibit improved resistance to slow crack growth and excellent strength retention at high temperatures up to 1400 C. Materials studied typically contain Y2O3 to metastably retain the high-temperature cubic and tetragonal polymorphs at room temperature. Al2O3-ZrO2 is of fundamental interest for creep studies because it combines a creep-resistant material, Al2O3, with a very low creep resistance material, ZrO2. Results on mechanical properties and microstructures of these materials will be used to define compositions for creep testing in future work. Substantial variations from the eutectic alumina to zirconia ratio can be tolerated without a loss in room-temperature strength. The effect of increasing Y2O3 addition on the room-temperature tensile strength of an Al2O3-ZrO2 material containing excess Al2O3 was examined at the NASA Glenn Research Center, where the materials were grown using Glenn's world-class laser growth facilities.
Fabrication and microstructure control studies were conducted on SiC, Si3N and composites based on Si3N. Charpy mode impact testing to 2400 F established that Si3N4/Mo composites have excellent potential. Attempts to fabricate composites of Si3N4 with superalloys, both by hot pressing and infiltration were largely unsuccessful in comparison to using Mo, Re, and Ta which are less reactive. Modest improvements in impact strength were realized for monolithic Si3N4; however, SiC strengths increased by a factor of six and now equal values achieved for Si3N4. Correlations of impact strength with material properties are discussed. Reduced MgO densification aid additions to Si3N4 were found to decrease densification kinetics, increase final porosity, decrease room temperature bend strength, increase high temperature bend strength, and decrease bend stress rupture properties. The decrease in bend strength at high temperature for fine grain size SiC suggested that a slightly larger grain size material with a nearly constant strength-temperature relation may prove desirable in the creep and stress rupture mode.
Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is an attractive method of processing, because no additional chemical reagents are needed. The electrochemical processing of molten oxides requires high surface area, inert anodes. Such electrodes need to be structurally robust at elevated temperatures (1400-1600 C), be resistant to thermal shock, have good electrical conductivity, be resistant to attack by molten oxide (silicate), be electrochemically stable and support high current density. Iridium with its high melting point, good oxidation resistance, superior high temperature strength and ductility is the most promising candidate for anodes in high temperature electrochemical processes. Several innovative concepts for manufacturing such anodes by electrodeposition of iridium from molten salt electrolyte (EL-Form process) were evaluated. Iridium electrodeposition to form of complex shape components and coating was investigated. Iridium coated graphite, porous iridium structure and solid iridium anodes were fabricated. Testing of electroformed iridium anodes shows no visible degradation. The result of development, manufacturing and testing of high surface, inert iridium anodes will be presented.
Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is an attractive method of processing, because no additional chemical reagents are needed. The electrochemical processing of molten oxides requires high surface area, inert anodes. Such electrodes need to be structurally robust at elevated temperatures (1400-1600?C), be resistant to thermal shock, have good electrical conductivity, be resistant to attack by molten oxide (silicate), be electrochemically stable and support high current density. Iridium with its high melting point, good oxidation resistance, superior high temperature strength and ductility is the most promising candidate for anodes in high temperature electrochemical processes. Several innovative concepts for manufacturing such anodes by electrodeposition of iridium from molten salt electrolyte (EL-Form? process) were evaluated. Iridium electrodeposition to form of complex shape components and coating was investigated. Iridium coated graphite, porous iridium structure and solid iridium anodes were fabricated. Testing of electroformed iridium anodes shows no visible degradation. The result of development, manufacturing and testing of high surface, inert iridium anodes will be presented.
This effort sought to exploit advanced single crystal tungsten-tantalum alloy material for fabrication of a high strength, high temperature arcjet anode. The use of this material is expected to result in improved strength, temperature resistance, and lifetime compared to state of the art polycrystalline alloys. In addition, the use of high electrical and thermal conductivity carbon-carbon composites was considered, and is believed to be a feasible approach. Highly conductive carbon-carbon composite anode capability represents enabling technology for rotating-arc designs derived from the Russian Scientific Research Institute of Thermal Processes (NIITP) because of high heat fluxes at the anode surface. However, for US designs the anode heat flux is much smaller, and thus the benefits are not as great as in the case of NIITP-derived designs. Still, it does appear that the tensile properties of carbon-carbon can be even better than those of single crystal tungsten alloys, especially when nearly-single-crystal fibers such as vapor grown carbon fiber (VGCF) are used. Composites fabricated from such materials must be coated with a refractory carbide coating in order to ensure compatibility with high temperature hydrogen. Fabrication of tungsten alloy single crystals in the sizes required for fabrication of an arcjet anode has been shown to be feasible. Test data indicate that the material can be expected to be at least the equal of W-Re-HfC polycrystalline alloy in terms of its tensile properties, and possibly superior. We are also informed by our colleagues at Scientific Production Association Luch (NP0 Luch) that it is possible to use Russian technology to fabricate polycrystalline W-Re-HfC or other high strength alloys if desired. This is important because existing engines must rely on previously accumulated stocks of these materials, and a fabrication capability for future requirements is not assured.
Better high temperature fibers are the key to high performance, light weight composite materials. However, current U.S. and Japanese fibers still have inadequate high temperature strength, creep resistance, oxidation resistance, modulus, stability, and thermal expansion match with some of the high temperature matrices being considered for future aerospace applications. In response to this clear deficiency, both countries have research and development activities underway. Once successful fibers are identified, their production will need to be taken from laboratory scale to pilot plant scale. In such efforts it can be anticipated that the Japanese decisions will be based on longer term criteria than those applied in the U.S. Since the initial markets will be small, short term financial criteria may adversely minimize the number and strength of U.S. aerospace materials suppliers to well into the 21st century. This situation can only be compounded by the Japanese interests in learning to make commercial products with existing materials so that when the required advanced fibers eventually do arrive, their manufacturing skills will be developed.
The mechanical properties of chromium, molybdenum, and tungsten alloys are reviewed with particular emphasis on high-temperature strength and low-temperature ductility. Precipitate strengthening is highly effective at 0.4 to 0.8 times the melting temperature in these metals, with HfC being most effective in tungsten and molybdenum, and Ta(B,C) most effective in chromium. Low-temperature ductility can be improved by alloying to promote rhenium ductilizing or solution softening. The low-temperature mechanical properties of these alloys appear related to electronic interactions rather than to the usual metallurgical considerations.
This paper compares the tensile properties of Cu-8Cr-4Nb material produced by VPS to material previously produced by extrusion. The microstructure of the VPS material is also presented. The combustion chamber liner of rocket motors represents an extreme materials application. The liner hot wall is exposed to a 2760 C (5000 F) flame while the cold side is exposed to cryogenic hydrogen liquid. Materials for use in the combustion chamber liner require a combination of high temperature strength, creep resistance, and low cycle fatigue resistance along with high thermal conductivity. The hot side is also subject to localized cycles between reducing and oxidizing environments that degrade the liner by a process called blanching. A new Cu-8 at.% Cr-4 at% Nb (Cu-8Cr-4Nb) alloy has been developed at NASA Lewis Research Center as a replacement for the currently used alloy, NARloy-z (Cu-3 wt.% Ag-0.5 wt.% Zr). The alloy is strengthened by a fine dispersion of Cr2Nb particles. The alloy has better mechanical properties than NARloy-Z while retaining most of the thermal conductivity of pure copper. The alloy has been successfully consolidated by extrusion and hot isostatic pressing (HIPing). However, vacuum plasma spraying (VPS) offers several advantages over prior consolidation methods. VPS can produce a near net shape piece with the profile of the liner. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the liner hot wall during the VPS deposition. The low oxygen VPS Cu-8Cr-4Nb exhibits a higher strength than Cu-8Cr-4Nb produced by extrusion at elevated temperatures and a comparable strength at room temperature. Moduli and ductility were not significantly different. However, the ability to produce parts to near-net shape and maintain the good elevated temperature tensile properties of the extruded Cu-8Cr-4Nb makes VPS an attractive processing method for fabricating rocket engine combustion liners.
High temperature strength of thermomechanical nickel dependent upon previous thermal and mechanical history, measuring elastic strain energy in matrix
Rapid solidification processing has been successfully used to create a uniform distribution of 30-nm TiB2 and HfC precipitates in a B2-ordered NiAl matrix, in order to enhance the matrix material's high-temperature strength and creep behavior. Attention is drawn to the question of the stability of carbide and boride dispersoids in an NiAl matrix during high-temperature exposures. The present alloys were consolidated at temperatures above 1422 K; the small size of precipitates in materials processed at such high temperatures gives an indication of their thermal stability, and further coarsening of the precipitates at elevated service temperatures is rendered unlikely by their low solubility in the matrix.
Recovery stress in shape memory alloys (SMAs), also known as blocking stress, is an important property generally obtained during heating under a dimensional constraint as the material undergoes the martensitic phase transformation. This property has been instinctively utilized in most SMA shape-setting procedures, and has been used in numerous applications such as fastening and joining, rock splitting, safety release mechanisms, reinforced composites, medical devices, and many other applications. The stress generation is also relevant to actuator applications where jamming loads (e.g., in case the actuator gets stuck and is impeded from moving) need to be determined for proper hardware sizing. Recovery stresses in many SMA systems have been shown to reach stresses in the order of 800 MPa, achieved via thermo-mechanical training such as pre-straining, heat treatments or other factors. With the advent of high strength, high temperature SMAs, recovery stress data has been rarely probed, and there is no information pertinent to the magnitudes of these stresses. Thus, the purpose of this work is to investigate the recovery stress capability of a precipitation strengthened, Ni50.3Ti29.7Hf20 (at.) high temperature SMA in uniaxial tension and compression. This material has been shown to exhibit outstanding strength and stability during constant-stress, thermal cycling, but no data exists on constant-strain thermal cycling. Several training routines were implemented as part of this work including isothermal pre-straining, isobaric thermal cycling, and isothermal cyclic training routines. Regardless of the training method used, the recovery stress was characterized using constant-strain (strain-controlled condition) thermal cycling between the upper and lower cycle temperatures. Preliminary results indicate recovery stresses in excess of 1.5 GPa were obtained after a specific training routine. This stress magnitude is significantly higher than conventional NiTi stress generation capability.