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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Bithermal Low-Cycle Fatigue Evaluation of Automotive Exhaust System Alloy SS409

This investigation provides, for the first time, cyclic strainrange-controlled, thermomechanical fatigue results for the ferritic stainless steel alloy SS409. The alloy has seen extensive application for automotive exhaust system components. The data were generated to calibrate the Total Strain Version of the Strainrange Partitioning (TS-SRP) method for eventual application to the design and durability assessment of automotive exhaust systems. The thermomechanical cyclic lifetime and cyclic stress-strain constitutive behavior for alloy SS409 were measured using bithermal tests cycling between isothermal extremes of 400 and 800 C. Lives ranged up to 10,000 cycles to failure with hold-times of 0.33 to 2.0 minutes. The bithermal fatigue behavior is compared to isothermal, strain-controlled fatigue behavior at both 400 and 800 C. Thermomechanical cycling was found to have a profound detrimental influence on the fatigue failure resistance of SS409 compared to isothermal cycling. Supplementary bithermal cyclic stress-strain constitutive tests with hold-times ranging from 40 seconds up to 1.5 hours were conducted to calibrate the TS-SRP equation for extrapolation to longer lifetime predictions. Observed thermomechanical (bithermal) fatigue lives correlated well with lives calculated using the calibrated TS-SRP equations: 70% of the bithermal fatigue data fall within a factor of 1.2 of calculated life; 85% within a factor of 1.4; and 100% within a factor of 1.8.

Lu, Gui-Ying↗
NASA NTRS1978

New alloys to conserve critical elements

Based on availability of domestic reserves, chromium is one of the most critical elements within the U.S. metal industry. New alloys having reduced chromium contents which offer potential as substitutes for higher chromium containing alloys currently in use are being investigated. This paper focuses primarily on modified Type 304 stainless steels having one-third less chromium, but maintaining comparable oxidation and corrosion properties to that of type 304 stainless steel, the largest single use of chromium. Substitutes for chromium in these modified Type 304 stainless steel alloys include silicon and aluminum plus molybdenum.

Stephens, J. R.↗
NASA NTRS1986

Acoustoelastic constants in dilute two-phase alloys

Acoustoelastic constants are calculated for two-phase alloys containing dilute concentrations of precipitates in a solid-solution matrix, on the basis of a model in which the precipitates are represented as a dilute elastic suspension of spherical particle inclusions in an infinite matrix. The longitudinal propagation velocity in the alloy is thereby obtained in terms of the precipitates' concentration and the elastic moduli of the two phases. Results are presented which indicate that the acoustoelastic constant of longitudinal waves in a dilute two-phase alloy varies linearly with the concentration of second-phase precipitates, in agreement with recent measurements in aluminum and steel alloys where the acoustoelastic constants changed linearly with the second phase's volume fraction.

Salama, K.↗
NASA NTRS2003

The Role of Convection and Growth Competition on Phase Selection in Microgravity

For a wide range of compositions, Fe-Cr-Ni alloys can solidify by a two-step process: a metastable solid forms first, subsequently transforming into the stable solid phase. This two-step solidification produces a profoundly different microstructure, and therefore different properties, in the final solid. The delay time between the two steps of the solidification process varies from microseconds to seconds. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the MSL-1 mission and in ground based electrostatic levitation testing at NASA MSFC, we know that convection also has a significant effect on the delay time. By examining the effect of convection on delay time over a wide range of convection, for several different alloys, we can gain a better understanding and better control of the microstructural evolution and final structure of stainless steel alloys. MSFC provides ESL for ground-based testing in a low-convection state, and the numerical modeling that enables estimation of the convection levels under the different process conditions.

Source record↗
NASA NTRS2014

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

This paper describes the results of a research program conducted to improve the understanding of fatigue crack growth rate behavior in the threshold growth rate region and to answer a question on the validity of threshold region test data. The validity question relates to the view held by some experimentalists that using the ASTM load shedding test method does not produce valid threshold test results and material properties. The question involves the fanning behavior observed in threshold region of da/dN plots for some materials in which the low R-ratio data fans out from the high R-ratio data. This fanning behavior or elevation of threshold values in the low R-ratio tests is generally assumed to be caused by an increase in crack closure in the low R-ratio tests. Also, the increase in crack closure is assumed by some experimentalists to result from using the ASTM load shedding test procedure. The belief is that this procedure induces load history effects which cause remote closure from plasticity and/or roughness changes in the surface morphology. However, experimental studies performed by the authors have shown that the increase in crack closure is a result of extensive crack tip bifurcations that can occur in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the fanning behavior which occurs in aluminum alloys is a function of intrinsic dislocation property of the alloy, and therefore, the fanned data does represent the true threshold properties of the material. However, for the corrosion sensitive steel alloys tested in laboratory air, the occurrence of fanning results from fretting corrosion at the crack tips, and these results should not be considered to be representative of valid threshold properties because the fanning is eliminated when testing is performed in dry air.

Forman, R. G.↗
NASA NTRS2014

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

The research results described in this paper presents a new understanding of the behavior of fatigue crack growth in the threshold region. It is believed by some crack growth experts that the ASTM load shedding test method does not produce true or valid threshold properties. The concern involves the observed fanning of threshold region da/dN data plots for some materials in which the low R-ratio data fans out or away from the high R-ratio data. This data fanning or elevation of threshold values is obviously caused by an increase in crack closure in the low R-ratio tested specimens. This increase in crack closure is assumed by some investigators to be caused by a plastic wake on the crack surfaces that was created during the load shedding test phase. This study shows that the increase in crack closure is the result of an extensive occurrence of crack bifurcation behavior in some materials, particularly in aluminum alloys, when the crack tip cyclic yield zone size becomes less than the grain size of the alloy. This behavior is related to the high stacking fault energy (SFE) property of aluminum alloys which results in easier slip characteristics. Therefore, the particular fanning behavior in aluminum alloys is a function of intrinsic dislocation property of the materials and that the fanned data represents valid material properties. However, for corrosion sensitive steel alloys used in this study the fanning was caused by a build-up of iron oxide at the crack tip from fretting corrosion.

Forman, Royce G.↗
NASA NTRS2001

The Effects of Shot and Laser Peening on Fatigue Life and Crack Growth in 2024 Aluminum Alloy and 4340 Steel

Fatigue and crack growth tests have been conducted on 4340 steel and 2024-T3 aluminum alloy, respectively, to assess the effects of shot peening on fatigue life and the effects of shot and laser peening on crack growth. Two current programs involving fixed and rotary-wing aircraft will not be using shot peened structures. Since the shot peening compressive residual stress depth is usually less than the 0.05-inch initial damage tolerance crack size, it is believed by some that shot peening should have no beneficial effects toward retarding crack growth. In this study cracks were initiated from an electronic-discharged machining flaw which was cycled to produce a fatigue crack of approximately 0.05-inches in length and then the specimens were peened. Test results showed that after peening the crack growth rates were noticeably slower when the cracks were fairly short for both the shot and laser peened specimens resulting in a crack growth life that was a factor of 2 to 4 times greater than the results of the average unpeened test. Once the cracks reached a length of approximately 0.1-inches the growth rates were about the same for the peened and unpeened specimens. Fatigue tests on 4340 steel showed that the endurance limit of a test specimen with a 0.002-inch-deep machining-like scratch was reduced by approximately 40 percent. However, if the "scratched" specimen was shot peened after inserting the scratch, the fatigue life returned to almost 100 percent of the unflawed specimens original fatigue life.

Everett, R. A., Jr.↗
NASA NTRS1983

Precise thermal control test demonstration on simulated space telescope main ring

A simulated section of the main ring of the Space Telescope, (ST) the part that holds the primary mirror, was manufactured and tested for thermal stability characteristics in a complex structural assembly. The other telescope subassemblies are also mounted on the main ring, which is constructed of a titanium alloy. The entire ring is wrapped in heater elements around the outside diameter to reduce the external temperature gradient effects by two orders of magnitude. A thermal vacuum test was performed using a stainless steel alloy tailored to represent the titanium ring's thermal characteristics. The tests examined the thermal performance and controllability of the test ring, the effects of a 24-hr slew manuever that produced worst-case environment changes, hot and cold simulation of predicted ST orbital thermal environments, and the effects of heater failure. Pointing and thermal control features were verified, but a heater failure on the 'on' side was found to quickly lead to exceeding the thermal design limits.

Bettini, R. G.↗
NASA NTRS1993

Application of hard coatings to substrates at low temperatures

BIRL, the industrial research laboratory of Northwestern University, has conducted unique and innovative research, under sponsorship from the NASA Marshall Space Flight Center (MSFC), in the application of hard, wear resistant coatings to bearing steels using the high-rate reactive sputtering (HRRS) process that was pioneered by Dr. William Sproul, the principal investigator on this program. Prior to this program, Dr. Sproul had demonstrated that it is possible to apply hard coatings such as titanium nitride (TiN) to alloy steels at low temperatures via the HRRS process without changing the metallurgical properties of the steel. The NASA MSFC program at BIRL had the specific objectives to: apply TiN to 440C stainless steel without changing the metallurgical properties of the steel; prepare rolling contact fatigue (RCF) test samples coated with binary hard coatings of TiN, zirconium nitride (ZrN), hafnium nitride (HfN), chromium nitride (CrN), and molybdenum nitride (MoN), and metal coatings of copper (Cu) and gold (Au); and develop new alloyed hard coatings of titanium aluminum nitride (Ti(0.5)Al(0.5)N), titanium zirconium nitride (Ti(0.5)Zr(0.5)N), and titanium aluminum vanadium nitride.

Sproul, William D.↗
NASA NTRS1978

Rolling element fatigue testing of gear materials

Rolling element fatigue lives of eleven alloys were evaluated. The eleven alloys studied were three nitriding alloys (Super Nitralloy, Nitralloy 135, and Nitralloy N), four case carburizing alloys (AISI 9310, CBS 600, CBS 1000M and Vasco X-2), and four throughhardening alloys (Vasco Matrix II,AISI W-1, AISI S-2 and AISI O-2). Several different heat treatments and/or melting processes were studied on the three carburizing alloy steels. Metallurgical analyses were made before and after the RC rig tests. Test data were statistically analyzed using the Weibull distribution function. B-10 lives were compared versus VIM-VAR AISI M-50 and carburized VAR AISI 9310, as reference alloys.

Nahm, A. H.↗
NASA NTRS2010

Experimental Evaluation of Fatigue Crack Initiation from Corroded Hemispherical Notches in Aerospace Structural Materials

A test program was developed and executed to evaluate the influence of corroded hemispherical notches on the fatigue crack initiation and propagation in aluminum 7075-T7351, 4340 steel, and D6AC steel. Surface enhancements such as shot peening and laser shock peening were also incorporated as part of the test effort with the intent of improving fatigue performance. In addition to the testing, fracture mechanics and endurance limit based analysis methods were evaluated to characterize the results with the objective of challenging typical assumptions used in modeling fatigue cracks from corrosion pits. The results specifically demonstrate that the aluminum and steel alloys behave differently with respect to fatigue crack initiation from hemispherical corrosion pits. The aluminum test results were bounded by the fracture mechanics and endurance limit models while exhibiting a general insensitivity to the residual stress field generated by shot peening. The steel specimens were better characterized by the endurance limit fatigue properties and did exhibit sensitivities to residual stresses from the shot peening and laser shock peening

Garcia, Daniel B.↗
NASA NTRS1983

Tribological and microstructural characteristics of ion-nitrided steels

Three steels AISI 4140, AISI 4340 and AISI 304 stainless steel were ion nitrided in a plasma consisting of a 75:25 mixture of H2:N2, sometimes with a trace of CH4. Their surface topography was characterized by SEM and two distinct compound phases were identified: the gamma and the epsilon. The core-case hardness profiles were also established. The low Cr alloy steels have an extended diffusion zone in contrast to the 304 stainless steels which have a sharp interface. The depth of ion-nitriding is increased as the Cr content is decreased. Friction tests reveal that the gamma surface phase has a lower coefficient of friction than the epsilon phase. The lowest coefficient of friction is achieved when both the rider and the specimen surface are ion nitrided.

Spalvins, T.↗
NASA NTRS1983

Tribological and microstructural characteristics of ion-nitrided steels

Three steels AISI 4140, AISI 4340 and AISI 304 stainless steel were ion nitrided in a plasma consisting of a 75:25 mixture of H2:N2, sometimes with a trace of CH4. Their surface topography was characterized by SEM and two distinct compound phases were identified: the gamma and the epsilon. The core-case hardness profiles were also established. The low Cr alloy steels have an extended diffusion zone in contrast to the 3034 stainless steels which have a sharp interface. The depth of ion-nitriding is increased as the Cr content is decreased. Friction tests reveal that the gamma surface phase has a lower coefficient of friction than the epsilon phase. The lowest coefficient of friction is achieved when both the rider and the specimen surface are ion nitrided. Previously announced in STAR as N83-24635

Spalvins, T.↗
NASA NTRS1985

Frictional and structural characterization of ion-nitrided low and high chromium steels

Low Cr steels AISI 41410, AISI 4340, and high Cr austenitic stainless steels AISI 304, AISI 316 were ion nitrided in a dc glow discharge plasma consisting of a 75 percent H2 - 25 percent N2 mixture. Surface compound layer phases were identified, and compound layer microhardness and diffusion zone microhardness profiles were established. Distinct differences in surface compound layer hardness and diffusion zone profiles were determined between the low and high Cr alloy steels. The high Cr stainless steels after ion nitriding displayed a hard compound layer and an abrupt diffusion zone. The compound layers of the high Cr stainless steels had a columnar structure which accounts for brittleness when layers are exposed to contact stresses. The ion nitrided surfaces of high and low Cr steels displayed a low coefficient of friction with respect to the untreated surfaces when examined in a pin and disk tribotester.

Spalvins, T.↗