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NASA NTRS1988

The effect of hydrogen on deformation substructure, flow and fracture in a nickel-base single crystal superalloy

The room temperature flow and fracture of a nickel-base single crystal gamma/gamma-/prime superalloy in the presence and absence of hydrogen is explored. The procedure of hydrogen-charging employed in this study provides a very high and uniform hydrogen concentration of the order of 5000 at.-ppm in the material. It is shown that the most compelling hydrogen-induced changes in deformation behavior are enhanced dislocation accumulation in the gamma matrix and extensive cross-slip of super-dislocations. The explanation of these changes is proposed. Both effects contribute to the increase of flow stress and the notable work hardening that occurs prior to fracture. Hydrogen enhanced strain localization in the gamma matrix leads to the dramatic loss of ductility and premature cracking, which manifests as failure macroscopically parallel to the 100-plane-oriented faces of gamma-prime precipitates. On the microscale, cracking, while limited to the gamma matrix, occurs parallel to multiple 111-plane-oriented slip systems.

Dollar, M.↗

NASA NTRS2006

Geometrically Nonlinear Static Analysis of 3D Trusses Using the Arc-Length Method

Rigorous analysis of geometrically nonlinear structures demands creating mathematical models that accurately include loading and support conditions and, more importantly, model the stiffness and response of the structure. Nonlinear geometric structures often contain critical points with snap-through behavior during the response to large loads. Studying the post buckling behavior during a portion of a structure's unstable load history may be necessary. Primary structures made from ductile materials will stretch enough prior to failure for loads to redistribute producing sudden and often catastrophic collapses that are difficult to predict. The responses and redistribution of the internal loads during collapses and possible sharp snap-back of structures have frequently caused numerical difficulties in analysis procedures. The presence of critical stability points and unstable equilibrium paths are major difficulties that numerical solutions must pass to fully capture the nonlinear response. Some hurdles still exist in finding nonlinear responses of structures under large geometric changes. Predicting snap-through and snap-back of certain structures has been difficult and time consuming. Also difficult is finding how much load a structure may still carry safely. Highly geometrically nonlinear responses of structures exhibiting complex snap-back behavior are presented and analyzed with a finite element approach. The arc-length method will be reviewed and shown to predict the proper response and follow the nonlinear equilibrium path through limit points.

Hrinda, Glenn A.↗

NASA NTRS1982

Creep and rupture of an ODS alloy with high stress rupture ductility

The creep and stress rupture properties of an oxide (Y2O3) dispersion strengthened nickel-base alloy, which also is strengthened by gamma-prime precipitates, was studied at 760 and 1093 C. At both temperatures, the alloy YDNiCrAl exhibits unusually high stress rupture ductility as measured by both elongation and reduction in area. Failure was transgranular, and different modes of failure were observed including crystallographic fracture at intermediate temperatures and tearing or necking almost to a chisel point at higher temperatures. While the rupture ductility was high, the creep strength of the alloy was low relative to conventional gamma prime strengthened superalloys in the intermediate temperature range and to ODS alloys in the higher temperature range. These findings are discussed with respect to the alloy composition; the strengthening oxide phases, which are inhomogeneously dispersed; the grain morphology, which is coarse and elongated and exhibits many included grains; and the second phase inclusion particles occurring at grain boundaries and in the matrix. The creep properties, in particular the high stress dependencies and high creep activation energies measured, are discussed with respect to the resisting stress model of creep in particle strengthened alloys.

Mcalarney, M. E.↗

NASA NTRS2006

Development of Laser Fabricated Ti-6Al-4V

Laser Engineered Net Shaping (LENS) depositions with Ti-6Al-4V gas-atomized powder were accomplished at five different temperatures, ranging from 30 to 400 C, imposed on the base plate. These base plate temperatures were employed in an effort to relieve stresses which develop during the deposition. Warpage of the base plate was monitored. Only a slight decline in warpage was observed as the base plate temperature was increased. Results indicate that substrate temperatures closer to the stress relief minimum of 480 C would relieve deposition stresses, though process parameters would likely need to be modified to compensate for the higher base plate temperature. The compositions of the as-received powder and the LENS deposited material were chemically analyzed. The oxygen content of the LENS material was 0.154 wt.% which is less than the maximum impurity limit of 0.2 percent for commercial Ti-6Al-4V alloys, but is over the limit allowed in ELI grade (0.13 percent). The level of oxygen in the commercial base plate used was only 0.0635 percent. Tensile specimens were machined from the LENS deposited material and tested in tension at room temperature. The ultimate and yield tensile stresses of the LENS material were about 1200 and 1150 MPa respectively, which is about 20 percent higher than the strengths of wrought Ti-6Al-4V. The higher strength of the LENS material was due to its fine structure and high oxygen content. The LENS deposits were not fully dense; voids were frequent at the interfaces between deposited layers. These dispersed sheets of voids were parallel to the longitudinal axis of the resulting tensile specimens. Apparently there was sufficient continuous, fully dense material longitudinally to enable the high strengths. Ductility was low in the LENS material. Percent elongation at failure in the LENS material was near 4 percent, which is less than half of what is usually expected from Ti-6Al-4V. The low ductility was caused by high oxygen levels, and the presence of voids. It is likely that the relatively high scan speeds used in our depositions contributed to the lack of full density in our LENS material.

deGroh, Henry C., III↗

NASA NTRS1991

The Mechanical Properties of a Ni-30Al-20Fe-0.05Zr Intermetallic Alloy in the Temperature Range 300-1200 K

Tensile tests were conducted on an extruded Ni-30(at. pct)Al-20Fe-0.05Zr intermetallic alloy in the temperature range 300-1200 K, and the microstructures were characterized by optical, scanning, and transmission electron microscopy. The alloy did not exhibit any room temperature ductility and failed by transgranular cleavage at a stress of about 710 MPa. This mode of fracture was observed at and below 873 K with the total ductility being less than 2.5 percent. However, the failure mode changed to dimpled fracture, triple point cracking, and rupture above 873 K. Scanning electron microscopy of the fracture surfaces revealed that transgranular cleavage failure had always originated at preexisting defects. In these cases, the fracture stress exhibited a good correlation with the defect size, in accordance with linear elastic fracture mechanics, where the critical stress intensity factor was estimated to be about 4 MPa sq rt m.

Raj, S. V.↗

NASA NTRS1983

Experimental deformation of polycrystalline H2O ice at high pressure and low temperature - Preliminary results

A preliminary study is carried out of involving 70 constant strain deformation tests on pure polycrystalline H2O ice under conditions covering most of the stability field of ice I sub h. Brittle failure of I sub h is found to be promoted by lower P, lower T, and higher strain rates. Ductile flow is found to be promoted by higher P, higher T, and lower strain rates. The brittle failure of ice I sub h is found to be most unusual. The fracture strength is a positive function of P only below 50 MPa. At pressures greater than this, the fracture strength is independent of P, and the fracture plane lies approximately 45 deg from the load axis. It is believed that existing extrapolation based on existing experimental data to Ganymede and Callisto may be badly in error.

Durham, W. B.↗

NASA NTRS1989

Stress corrosion study of PH13-8Mo stainless steel using the Slow Strain Rate Technique

The need for a fast and reliable method to study stress corrosion in metals has caused increased interest in the Slow Strain Rate Technique (SSRT) during the last few decades. PH13-8MoH950 and H1000 round tensile specimens were studied by this method. Percent reduction-in-area, time-to-failure, elongation at fracture, and fracture energy were used to express the loss in ductility, which has been used to indicate susceptibility to stress corrosion cracking (SCC). Results from a 3.5 percent salt solution (corrosive medium) were compared to those in air (inert medium). A tendency to early failure was found when testing in the vicinity of 1.0 x 10(-6) mm/mm/sec in the 3.5 percent salt solution. PH13-8Mo H1000 was found to be less likely to suffer SCC than PH13-8Mo H950. This program showed that the SSRT is promising for the SCC characterization of metals and results can be obtained in much shorter times (18 hr for PH steels) than those required using conventional techniques.

Torres, Pablo D.↗

NASA NTRS1966

Boron-deoxidized copper withstands brazing temperatures

Boron-deoxidized high-conductivity copper is used for fabrication of heat transfer components that are brazed in a hydrogen atmosphere. This copper has high strength and ductility at elevated temperatures and does not exhibit massive intergranular failure.

Schmidt, E. H.↗

NASA NTRS2023

Effects of Strain Rate and Surface Finish on Tensile Properties in High Pressure Hydrogen — A Case Study for LP-DED NASA HR-1

NASA has advanced NASA HR-1 as a solution for liquid rocket engine components that operate in hydrogen rich environments using various AM techniques. The NASA HR-1 for AM applications was specifically formulated for high ductility in high pressure gaseous hydrogen environment in addition to high strength and low cycle fatigue (LCF) resistance. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good LCF performance, and high elongation and strength for components in medium heat flux environments. NASA has completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. The main objective of this investigation is to better understand the effects of tensile test strain rate and specimen surface finish on the amount of tensile ductility degradation in high pressure gaseous hydrogen environments. Performing smooth tensile tests in high pressure hydrogen and nitrogen environments can serve as a rapid and economical screening method to determine the relative susceptibility of materials to HEE. This paper presents the tensile test results for LP-DED NASA HR-1 in hydrogen and details the material evaluation on the effects of strain rate and surface finish condition on surface cracking behavior and fracture characteristics. The resistance to HEE for LP-DED NASA HR-1 and the wrought alloy is compared under the same testing conditions. Loss of tensile ductility is quantified in terms of changes in elongation at failure in hydrogen to compare HEE susceptibility. The most suitable strain rate and specimen surface finish condition for future HEE screening testing at MSFC are recommended.

Additive manufacturing↗

NASA NTRS1991

A model for predicting high-temperature fatigue failure of a W/Cu composite

The material studied, a tungsten-fiber-reinforced, copper-matrix composite, is a candidate material for rocket nozzle liner applications. It was shown that at high temperatures, fatigue cracks initiate and propagate inside the copper matrix through a process of initiation, growth, and coalescence of grain boundary cavities. The ductile tungsten fibers neck and rupture locally after the surrounding matrix fails, and complete failure of the composite then ensues. A simple fatigue life prediction model is presented for the tungsten/copper composite system.

Verrilli, M. J.↗

NASA NTRS1984

Tensile Fracture of Ductile Materials

For brittle materials, circular voids play an important role relative to fracture, intensifing both tensile and compressive stresses. A maximum intensified tensile stress failure criterion applies quite well to brittle materials. An attempt was made to explore the possibility of extending the approach to the tensile fracture of ductile materials. The three dimensional voids that exist in reality are modelled by circular holes in sheet metal. Mathematical relationships are sought between the shape and size of the hole, after the material is plastically deformed, and the amount of deformation induced. Then, the effect of hole shape, size and orientation on the mechanical properties is considered experimentally. The presence of the voids does not affect the ultimate tensile strength of the ductile materials because plastic flow wipes out the stress intensification caused by them. However, the shape and orientation of the defect is found to play an important role in affecting the strain at fracture.

Pai, D. M.↗

NASA NTRS2013

A Study of Solder Alloy Ductility for Cryogenic Applications

For aerospace applications it is important to understand the mechanical performance of components at the extreme temperature conditions seen in service. For solder alloys used in microelectronics, cryogenic temperatures can prove problematic. At low temperatures Sn-based solders undergo a ductile to brittle transition that leads to brittle cracks, which can result in catastrophic failure of electronic components, assemblies and spacecraft payloads. As industrial processes begin to move away from Pb-Sn solder, it is even more critical to characterize the behavior of alternative Sn-based solders. Here we report on initial investigations using a modified Charpy test apparatus to characterize the ductile to brittle transformation temperature of nine different solder systems.

solders↗

NASA NTRS1984

Effects of processing and microstructure on the fatigue behaviour of the nickel-base superalloy Rene95

Forms of the nickel-base superalloy Rene95 produced by three processing methods were evaluated in tensile, low cycle fatigue and fatigue crack propagation tests at 540 and 650 C. Two powder-metallurgy (PM) forms, hot-isostatically-pressed and extruded-and-forged, and a conventionally cast-and-wrought form were all given the same heat treatment. The extruded-and-forged form showed superior fatigue life in low strain range tests though the two PM forms exhibited nearly identical mechanical behavior in all other respects. Further, this life difference could not be explained by significant differences in the types, sizes or shapes of the defects initiating failure. The cast-and-wrought Rene95, however, had lower strength, ductility and fatigue life, but higher fatigue crack propagation resistance because of a larger grain size. It did not exhibit the environmentally-assisted intergranular mode of propagation which occurs in PM Rene95 and other fine-grained superalloys at these test temperatures and frequencies.

Miner, R. V.↗

NASA NTRS1994

Ability of the total strain version of strainrange partitioning to characterize thermomechanical fatigue behavior

Strainrange partitioning (SRP) was originally developed on an inelastic strain basis for isothermal fatigue in the high-strain regime where the inelastic strainrange could be determined accurately. However, most power-generating equipment operates in the regime where the inelastic strains are small and difficult to determine with any degree of accuracy. This shortcoming led to the development of the total strain version of SRP (TS-SRP). Power-generating equipment seldom operates under isothermal conditions, and isothermal life prediction methods cannot be depended on to predict the lives of anisothermal cycles. To overcome this shortcoming, a method was proposed for extending TS-SRP to characterize anisothermal fatigue behavior and to predict the lives of thermomechanical fatigue (TMF) cycles using apppropriate anisothermal data. The viability of this method, referred to as TMF/TS-SRP, was demonstrated using TMF data for two high-temperature aerospace alloys. In this report, data from the literature are used to examine the ability of TMF/TS-SRP to characterize the failure and flow behavior of three low-strength, high-ductility alloys widely used for ground-based power-generating equipment. The three alloys are type 304 stainless steel, 1Cr-1Mo-0.25V steel, and 2.25Cr-1Mo steel. Because of the limited nature of the data, it was possible to evaluate the characterization, but not the predictive capability of TMF/TS-SRP.

Saltsman, James F.↗

NASA NTRS2014

Use of Slow Strain Rate Tensile Testing to Assess the Ability of Several Superalloys to Resist Environmentally-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720(TradeMark) ATI 718Plus(Registered TradeMark) alloy, Haynes 282(Trademark), and Inconel 740(TradeMark) Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

fatigue(materials)↗

NASA NTRS2014

Slow Strain Rate Tensile Testing to Assess the Ability of Superalloys to Resist Environment-Assisted Intergranular Cracking

Intergranular fatigue crack initiation and growth due to environmental degradation, especially at notched features, can often limit the fatigue life of disk superalloys at high temperatures. For clear comparisons, the effects of alloy composition on cracking in air needs to be understood and compared separately from variables associated with notches and cracks such as effective stress concentration, plastic flow, stress relaxation, and stress redistribution. The objective of this study was to attempt using simple tensile tests of specimens with uniform gage sections to compare the effects of varied alloy composition on environment-assisted cracking of several powder metal and cast and wrought superalloys including ME3, LSHR, Udimet 720, ATI 718Plus alloy, Haynes 282, and Inconel 740. Slow and fast strain-rate tensile tests were found to be a useful tool to compare propensities for intergranular surface crack initiation and growth. The effects of composition and heat treatment on tensile fracture strain and associated failure modes were compared. Environment interactions were determined to often limit ductility, by promoting intergranular surface cracking. The response of various superalloys and heat treatments to slow strain rate tensile testing varied substantially, showing that composition and microstructure can significantly influence environmental resistance to cracking.

Heat resistant alloys↗

NASA NTRS2015

The Safe Removal of Frozen Air from the Annulus of an LH2 Storage Tank

Large Liquid Hydrogen (LH2) storage tanks are vital infrastructure for NASA. Eventually, air may leak into the evacuated and perlite filled annular region of these tanks. Although the vacuum level is monitored in this region, the extremely cold temperature causes all but the helium and neon constituents of air to freeze. A small, often unnoticeable pressure rise is the result. As the leak persists, the quantity of frozen air increases, as does the thermal conductivity of the insulation system. Consequently, a notable increase in commodity boil-off is often the first indicator of an air leak. Severe damage can result from normal draining of the tank. The warming air will sublimate which will cause a pressure rise in the annulus. When the pressure increases above the triple point, the frozen air will begin to melt and migrate downward. Collection of liquid air on the carbon steel outer shell may chill it below its ductility range, resulting in fracture. In order to avoid a structural failure, as described above, a method for the safe removal of frozen air is needed. A thermal model of the storage tank has been created using SINDA/FLUINT modeling software. Experimental work is progressing in an attempt to characterize the thermal conductivity of a perlite/frozen nitrogen mixture. A statistical mechanics model is being developed in parallel for comparison to experimental work. The thermal model will be updated using the experimental/statistical mechanical data, and used to simulate potential removal scenarios. This paper will address methodologies and analysis techniques for evaluation of two proposed air removal methods.

cryogenic insulation↗

NASA NTRS1990

Fundamental aspects and failure modes in high-temperature composites

Fundamental aspects and attendant failure mechanisms for high-temperature composites are summarized. These include in situ matrix behavior, load transfer, limits on matrix ductility to survive a given number of cyclic loadings, fundamental parameters which govern thermal stresses, vibration stresses and impact resistance, as well as their attendant failure mechanisms and failure sequences. The resulting guidelines are presented in terms of simple equations which are suitable for the preliminary assessment of the merits of a particular high-temperature composite in a specific application.

Chamis, C. C.↗