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At least 55 records · Page 3

Development of high-speed balancing technology

An investigation into laser material removal showed that laser burns act in a manner typical of mechanical stress raisers causing a reduction in fatigue strength; the fatigue strength is lowered relative to the smooth specimen fatigue strength. Laser-burn zones were studied for four materials: Alloy Steel 4340, Stainless Steel 17-4 PH, Inconel 718, and Aluminum Alloy 6061-T6. Calculations were made of stress concentration factors K, for laser-burn grooves of each material type. A comparison was then made to experimentally determine the fatigue strength reduction factor. These calculations and comparisons indicated that, except for the 17-4 PH material, good agreement (a ratio of close to 1.0) existed between Kt and Kf. The performance of the 17-4 PH material has been attributed to early crack initiation due to the lower fatigue resistance of the soft, unaged laser-affected zone. Also covered in this report is the development, implementation, and testing of an influence coefficient approach to balancing a long, slender shaft under applied-torque conditions. Excellent correlation existed between the analytically predicted results and those data obtained from testing.

Demuth, R.↗

Plasma Spray for Difficult-To-Braze Alloys

Nickel plating on surfaces makes brazing easier for some alloys. Sometimes nickel plating may not be feasible because of manufacturing sequence, size of hardware, or lack of suitable source for nickel plating. Alternative surface preparation in such cases is to grit-blast surface lightly and then plasma-spray 1 1/2 to 2 mils of fine nickel powder or braze-alloy material directly on surface. Powder is sprayed from plasma gun, using argon as carrier gas to prevent oxidation of nickel or braze alloy.

Brennan, A.↗

Fracture analysis of various cracked configurations in sheet and plate materials

A two-parameter fracture criterion has been derived which relates the linear-elastic stress-intensity factor at failure, the elastic nominal failure stress, and two material parameters. The fracture criterion was applied to center-crack tension, compact, and notch-bend fracture specimens made of steel, titanium, or aluminum alloy materials tested at room temperature. The fracture data included a wide range of crack lengths, specimen widths, and thicknesses. The materials analyzed had a wide range of tensile properties. Failure stresses calculated using the criterion agreed well (plus or minus 10 percent) with experimental failure stresses. The criterion was also found to correlate fracture data from different specimen types (such as center-crack tension and compact specimens), within plus or minus 10 percent for the same material, thickness, and test temperature.

Newman, J. C., Jr.↗

Crack Growth Behavior in the Threshold Region for High Cycle Fatigue Loading

This presentation describes results obtained from a research project conducted at the NASA Johnson Space Center (JSC) that was jointly supported by the FAA Technical Center and JSC. The JSC effort was part of a multi-task FAA program involving several U.S. laboratories and initiated for the purpose of developing enhanced analysis tools to assess damage tolerance of rotorcraft and aircraft propeller systems. The research results to be covered in this presentation include a new understanding of the behavior of fatigue crack growth in the threshold region. This behavior is important for structural life analysis of aircraft propeller systems and certain rotorcraft structural components (e.g., the mast). These components are often designed to not allow fatigue crack propagation to exceed an experimentally determined fatigue crack growth threshold value. During the FAA review meetings for the program, disagreements occurred between the researchers regarding the observed fanning (spread between the da/dN curves of constant R) in the threshold region at low stress ratios, R. Some participants believed that the fanning was a result of the ASTM load shedding test method for threshold testing, and thus did not represent the true characteristics of the material. If the fanning portion of the threshold value is deleted or not included in a life analysis, a significant penalty in the calculated life and design of the component would occur. The crack growth threshold behavior was previously studied and reported by several research investigators in the time period: 1970-1980. Those investigators used electron microscopes to view the crack morphology of the fatigue fracture surfaces. Their results showed that just before reaching threshold, the crack morphology often changed from a striated to a faceted or cleavage-like morphology. This change was reported to have been caused by particular dislocation properties of the material. Based on the results of these early investigations, a program was initiated at JSC to repeat these examinations on a number of aircraft structural alloys that were currently being tested for obtaining fatigue crack growth properties. These new scanning electron microscope (SEM) examinations of the fatigue fracture faces confirmed the change in crack morphology in the threshold crack tip region. In addition, SEM examinations were further performed in the threshold crack-tip region before breaking the specimens open (not done in the earlier published studies). In these examinations, extensive crack forking and even 90-degree crack bifurcations were found to have occurred in the final threshold crack-tip region. The forking and bifurcations caused numerous closure points to occur that prevented full crack closure in the threshold region, and thus were the cause of the fanning at low-R values. Therefore, we have shown that the fanning behavior was caused by intrinsic dislocation properties of the different alloy materials and were not the result of a plastic wake that remains from the load-shedding test phase. Also, to accommodate the use of da/dN data which includes fanning at low R-values, an updated fanning factor term has been developed and will be implemented into the NASGRO fatigue crack growth software. The term can be set to zero if it is desired that the fanning behavior is not be modeled for particular cases, such as when fanning is not a result of the intrinsic properties of a material.

Forman, Royce G.↗

Outer skin protection of columbium Thermal Protection System (TPS) panels

A coated columbium alloy material system 0.04 centimeter thick was developed which provides for increased reliability to the load bearing character of the system in the event of physical damage to and loss of the exterior protective coating. The increased reliability to the load bearing columbium alloy (FS-85) was achieved by interposing an oxidation resistant columbium alloy (B-1) between the FS-85 alloy and a fused slurry silicide coating. The B-1 alloy was applied as a cladding to the FS-85 and the composite was fused slurry silicide coated. Results of material evaluation testing included cyclic oxidation testing of specimens with intentional coating defects, tensile testing of several material combinations exposed to reentry profile conditions, and emittance testing after cycling of up to 100 simulated reentries. The clad material, which was shown to provide greater reliability than unclad materials, holds significant promise for use in the thermal protection system of hypersonic reentry vehicles.

Culp, J. D.↗

Effects of constraint on crack growth under aircraft spectrum loading

The objective is to study the effects of constraint on fatigue crack growth under aircraft spectrum loading. A plasticity-induced crack-closure model that accounts for constraint variations during the transition from flat-to-slant crack growth was used to correlate crack-growth rate data under constant-amplitude loading and to calculate crack growth under simulated aircraft spectrum loading. The model was applied to several thin-sheet aluminum alloy materials. Under laboratory air conditions, the transition was shown to be related to the size of the cyclic plastic zone based on the effective stress-intensity factor range for several sheet materials and thicknesses. Results from three-dimensional, elastic-plastic, finite-element analyses of a flat, straight-through crack in a thin-sheet aluminum alloy specimen showed a constraint loss similar to that assumed in the model. Using test data and the closure model, the location of the constraint-loss regime in terms of growth rate and the value of the constraint factor at these rates were determined by trial and error. The model was then used to calculate crack growth under the TWIST spectrum. The calculated results agreed reasonably well with test data. In general, the model predicted shorter crack-growth lives than tests under the TWIST spectrum by about 40 percent. For the TWIST spectrum clipped at Level 3, the calculated lives were within about 20 percent. The results demonstrated that constraint variations, especially for thin-sheet alloys, should be accounted for to predict crack growth under typical aircraft spectra.

Newman, J. C., Jr.↗

Smart materials fabrication and materials for micro-electro-mechanical systems; Symposium Proceedings, San Francisco, CA, Apr. 28-30, 1992

A conference on the rapidly developing fields of `smart materials' and micro-electro-mechanical systems produced papers in the areas of fabrication and characterization of ferroelectric thin films; polycrystalline silicon; optical, chemical, and biological sensors; thin film shape memory alloys; materials characterization; and alternative materials and applications.

Jardine, A. Peter↗

InGaAlAsPN: A Materials System for Silicon Based Optoelectronics and Heterostructure Device Technologies

A new material system is proposed for silicon based opto-electronic and heterostructure devices; the silicon lattice matched compositions of the (In,Ga,Al)-(As,P)N 3-5 compounds. In this nitride alloy material system, the bandgap is expected to be direct at the silicon lattice matched compositions with a bandgap range most likely to be in the infrared to visible. At lattice constants ranging between those of silicon carbide and silicon, a wider bandgap range is expected to be available and the high quality material obtained through lattice matching could enable applications such as monolithic color displays, high efficiency multi-junction solar cells, opto-electronic integrated circuits for fiber communications, and the transfer of existing 3-5 technology to silicon.

Broekaert, T. P. E.↗

Quench Module Insert (QMI) and the Diffusion Module Insert (DMI) Furnace Development

The Quench Module Insert (QMI) and the Diffusion Module Insert (DMI) are microgravity furnaces under development at Marshall Space Flight Center. The furnaces are being developed for the first Materials Science Research Rack (MSRR-1) of the Materials Science Research Facility (MSRF), one of the first International Space Station (ISS) scientific payloads. QMI is a Bridgman furnace with quench capability for studying interface behavior during directional solidification of metallic and alloy materials. DMI will be a Bridgman-Stockbarger furnace to study diffusion processes in semiconductors. The design for each insert, both QMI and DMI, is driven by specific science, operations and safety requirements, as well as by constraints arising from resource limitations, such as volume, mass and power. Preliminary QMI analysis and testing indicates that the design meets these requirements.

Crouch, Myscha R.↗

Erosion/corrosion of turbine airfoil materials in the high-velocity effluent of a pressurized fluidized coal combustor

Four candidate turbine airfoil superalloys were exposed to the effluent of a pressurized fluidized bed with a solids loading of 2 to 4 g/scm for up to 100 hours at two gas velocities, 150 and 270 m/sec, and two temperatures, 730 deg and 795 C. Under these conditions, both erosion and corrosion occurred. The damaged specimens were examined by cross-section measurements, scanning electron and light microscopy, and X-ray analysis to evaluate the effects of temperature, velocity, particle loading, and alloy material. Results indicate that for a given solids loading the extent of erosion is primarily dependent on gas velocity. Corrosion occurred only at the higher temperature. There was little difference in the erosion/corrosion damage to the four alloys tested under these severe conditions.

Zellars, G. R.↗

Fracture analysis of various cracked configurations in sheet and plate materials

A two-parameter fracture criterion was derived which relates the linear-elastic stress-intensity factor at failure, the elastic nominal failure stress, and two material parameters. The fracture criterion was used previously to analyze fracture data for surface- and through-cracked sheet and plate specimens under tensile loading. The fracture criterion was applied to center-crack tension, compact, and notch-band fracture specimens made of steel, titanium, or aluminum alloy materials tested at room temperature. The fracture data included a wide range of crack lengths, specimen widths, and thicknesses. The materials analyzed had a wide range of tensile properties. Failure stresses calculated using the criterion agreed well (plus or minus 10 percent) with experimental failure stresses. The criterion was also found to correlate fracture data from different specimen types (such as center-crack tension and compact specimens), within plus or minus 10 percent for the same material, thickness, and test temperature.

Newman, J. C., Jr.↗

An Eddy Current Case Study using NASA’s Transfer Function and Limited-Sample Probability of Detection Guidebooks

Probability of detection (POD) requirements for NASA fracture-critical human-rated systems can be met by (1) claiming ‘similarity’ to NASA Standard Nondestructive Evaluation (NDE) flaw sizes or (2) by inspector-specific POD demonstration, known as NASA Special NDE. Standard NDE flaw sizes are intended to represent the detection capability of most qualified inspectors, and were primarily based on POD studies in the development of the Space Shuttle Program Orbiter fracture control plan. However, these Standard NDE flaw sizes were based on fatigue cracks in flat panels of one material alloy over a limited range of panel thicknesses. While the POD study was comprehensive, the inspection conditions are relatively narrow. An evaluation of similarity between the Standard NDE POD study and flight component conditions is required to apply Standard NDE to specific flight component inspections. A similarity evaluation may include differences in materials, surface finish, component geometry (e.g., curvature, corners, welds), and inspection access. Similarity is typically based on a qualitative engineering evaluation. Recently, NASA published a quantitative methodology to assess similarity. If similarity is not supported by test and analysis, then the methodology provides a transfer function of flaw size for Special NDE POD demonstration. NASA recommends that Special POD demonstrations use flaws that are flight-like or more difficult to detect than flight component flaws, which are commonly induced fatigue cracks. Often, it is not feasible to induce fatigue cracks in flight component geometry, and therefore, a simpler representative geometry is used, commonly a flat panel, for POD demonstration. Inducing cracks in simple geometry specimens can be time-consuming and expensive, and thus, minimizing the number of flawed specimens is desired. Traditionally, NASA Special NDE demonstration was limited to MIL-HDBK-1823A methods or the binomial point-estimate method (PEM), commonly known as 29/29. Recently, NASA published a limited-sample POD (LS-POD) methodology for signal-response NDE techniques (e.g., eddy current) that provides POD demonstration with fewer specimens than previous approaches. LS-POD suggests a minimum of 10 flawed specimens, compared to 29 in the PEM and the suggested minimum of 40 from MIL-HDBK-1823A. The methodology also includes new guidance on evaluating the probability of false calls. In this presentation, these new transfer function and LS-POD methodologies are described and illustrated through an eddy current detection capability of far-side flaws on thin welded panels. A geometry-based transfer function is developed using electro-discharge machined (EDM) notches in flight component and simple geometry to estimate the Special NDE flaw size that is representative of the critical initial flaw size required by the fracture analysis. Then, fatigue cracks are induced in simple flat panels of the transferred flaw size, and the LS-POD methodology is used for Special NDE demonstration.

P. A. Parker↗

Improvement in the Shape Memory Response of Ti50.5Ni24.5Pd25 High-Temperature Shape Memory Alloy with Scandium Microalloying

A Ti(50.5)Ni(24.5)Pd25 high-temperature shape memory alloy (HTSMA) is microalloyed with 0.5 at. pct scandium (Sc) to enhance its shape-memory characteristics, in particular, dimensional stability under repeated thermomechanical cycles. For both Ti(50.5)Ni(24.5)Pd25 and the Sc-alloyed material, differential scanning calorimetry is conducted for multiple cycles to characterize cyclic stability of the transformation temperatures. The microstructure is evaluated using electron microscopy, X-ray diffractometry, and wavelength dispersive spectroscopy. Isobaric thermal cycling experiments are used to determine transformation temperatures, dimensional stability, and work output as a function of stress. The Sc-doped alloy displays more stable shape memory response with smaller irrecoverable strain and narrower thermal hysteresis than the baseline ternary alloy. This improvement in performance is attributed to the solid solution hardening effect of Sc.

Atli, K. C.↗

Microsegregation in directionally solidified Pb-8.4 at. pct Au alloy

The dependence of microsegregation behavior on growth rate and thermal gradient has been examined in a Pb-8.4 at. pct Au alloy material partially directionally solidified and quenched. The composition of the quenched 'liquid' at the dendrite tip (Ct), that of the eutectic-like solid phase freezing from the interdendritic liquid at the base of dendrite (Cse), the volume fraction of this eutectic-like region (fe), and solute profiles in the interdendritic quenched liquid and ahead of the dendrite have been measured. Two dendritic growth models for solidification of a binary alloy melt in a positive thermal gradient at the liquid-solid interface, one for dendrites with 'minimum undercooled dendrite tip' and the other for an Ivantsov type of dendrite with 'marginally stable tip', have been examined for a quantitative comparison with measured values of Ct, Cse, and fe. Convection in the melt, possibly due to horizontal density gradients, is found to be a serious limitation for theoretical understanding of the observed experimental behavior and meaningful comparison of theories.

Tewari, S. N.↗

FNAS modify matric and transparent experiments

Monotectic alloy materials are created by rapid melt/rapid solidification processing on the NASA KC-135. Separation of the uniform liquid into two liquids may occur by either of two processes; spinodal decomposition or nucleation followed by growth. In the first case, the liquid is unstable to composition waves, which form and grow, giving liquids of two different compositions. In the latter process discrete particles of the second liquid phase form via thermal fluctuations and then grow by diffusion. The two processes are very different, with the determining process being dictated by temperature, composition, and thermodynamic characteristics of the alloy. The first two quantities are process variables, while the third is determined by electronic interactions between the atoms in the alloy. In either case the initial alloy decomposition is followed by coarsening, resulting in growth of the particle size at nearly constant volume fraction. In particular, reduced gravity experiments on monotectic solutions have shown a number of interesting results in the KC-135. Monotectic solutions exhibit a miscibility gap in the liquid state, and consequently, gravity driven forces can dominate the solidification parameters at 1 g. In reduced gravity however, the distribution of the phases is different, resulting in new and interesting microstructures. The Rapid Melt/Rapid Quench Furnace allows one to melt a sample and resolidify it in one parabola of the KC-135's flight path, thus eliminating any accumulative influence of multiple parabolas to affect the microstructure of the material.

Smith, Guy A.↗