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NASA NTRS1975

Acoustic emission characteristics of copper alloys under low-cycle fatigue conditions

The acoustic emission (AE) characteristics of pure copper, zirconium-copper, and several copper alloys were determined to develop nondestructive evaluation schemes of thrust chambers through AE techniques. The AE counts rms voltages, frequency spectrum, and amplitude distribution analysis evaluated AE behavior under fatigue loading conditions. The results were interpreted with the evaluation of wave forms, crack propagation characteristics, as well as scanning electron fractographs of fatigue-tested samples. AE signals at the beginning of a fatigue test were produced by a sample of annealed alloys. A sample of zirconium-containing alloys annealed repeatedly after each fatigue loading cycle showed numerous surface cracks during the subsequent fatigue cycle, emitting strong-burst AE signals. Amplitude distribution analysis exhibits responses that are characteristic of certain types of AE signals.

Krampfner, Y.↗

NASA NTRS1980

The effect of zirconium on the isothermal oxidation of nominal Ni-14Cr-24Al alloys

The isothermal oxidation of Ni-14Cr-24Al-xZr-type alloys was performed in still air at 1100, 1150, and 1200 C for times up to 200 hr. The zirconium content of the alloys varied from 0-0.63 atom percent (a/o). The oxidized surfaces were studied by optical microscopy, X-ray diffraction, and scanning electron microscopy. The base alloy was an alumina former with the zirconium-containing alloys also developing some ZrO2. The addition of zirconium above 0.066 a/o increased the rate of weight gain relative to the base alloy. Due to oxide penetratio, the weight gain increased with Zr content; however, the scale thickness did not increase. The Zr did increase the adherence of the oxide, particularly at 1200 C. The delta W/A vs. time data fit the parabolic model of oxidation. The specific diffusion mechanism operative could not be identified by analysis of the calculated activation energies. Measurements of the Al2O3 scale lattice constants yielded the same values for all alloys.

Kahn, A. S.↗

NASA NTRS2016

Rapid Quench in an Electrostatic Levitator

The Electrostatic Levitation (ESL) Laboratory at the NASA Marshall Space Flight Center (MSFC) is a unique facility for investigators studying high-temperature materials. The ESL laboratory’s main chamber has been upgraded with the addition of a rapid quench system. This system allows samples to be dropped into a quench vessel that can be filled with a low melting point material, such as a gallium or indium alloy, as a quench medium. Thereby allowing rapid quenching of undercooled liquid metals. Up to eight quench vessels can be loaded into a wheel inside the chamber that is indexed with control software. The system has been tested successfully with samples of zirconium, iron-cobalt alloys, iron-chromium-nickel, titanium-zirconium-nickel alloys, and a silicon-cobalt alloy. This new rapid quench system will allow materials science studies of undercooled materials and new materials development. The system is described and some initial results are presented.

SanSoucie, Michael P.↗

NASA NTRS1973

High temperature, low cycle fatigue of copper-base alloys in argon. Part 3: Zirconium-copper; thermal-mechanical strain cycling, hold-time and notch fatigue results

The low-cycle fatigue characteristics of smooth bar and notched bar specimens (hourglass shape) of zirconium-copper, 1/2 Hard, material (R-2 Series) were evaluated at room temperature in axial strain control. Over the fatigue life range from about 300 to 3000 cycles the ratio of fatigue life for smooth bar to fatigue life for notched bar remained constant at a value of about 6.0. Some additional hold-time data for the R-2 alloy tested in argon at 538 C are reported. An analysis of the relaxation data obtained in these hold-time tests is also reported and it is shown that these data yield a fairly consistent correlation in terms of instantaneous stress rate divided by instantaneous stress. Two thermal-mechanical strain cycling tests were also performed using a cyclic frequency of 4.5 cycles per hour and a temperature cycling interval from 260 to 538 C. The fatigue life values in these tests were noticeably lower than that observed in isothermal tests at 538 C.

Conway, J. B.↗

NASA NTRS1976

Experimental and theoretical investigation of fatigue life in reusable rocket thrust chambers

During a test program to investigate low-cycle thermal fatigue, 13 rocket combustion chambers were fabricated and cyclically test fired to failure. Six oxygen-free, high-conductivity (OFHC) copper and seven Amzirc chambers were tested. The failures in the OFHC copper chambers were not typical fatigue failures but are described as creep rupture enhanced by ratcheting. The coolant channels bulged toward the chamber centerline, resulting in progressive thinning of the wall during each cycle. The failures in the Amzirc alloy chambers were caused by low-cycle thermal fatigue. The zirconium in this alloy was not evenly distributed in the chamber materials. The life that was achieved was nominally the same as would have been predicted from OFHC copper isothermal test data.

Hannum, N. P.↗

NASA NTRS1981

The effect of zirconium on the cyclic oxidation of NiCrAl alloys

This paper examines results with cyclic oxidation tests of Ni(9-20) Cr(15-30) Al-(x)Zr alloys carried out at 1100 C and 1200 C in static air. The concentration of zirconium varies from 0 to 0.63 atomic percent. Significant aluminum penetration is found in metallographic and electron microscopic examination of oxidized surfaces. Small amounts of zirconium lead to minimal penetration, and with increased zirconium content pronounced oxide penetration is observed.

Barrett, C. A.↗

NASA NTRS1991

Chemical compatibility of cartridge materials

This twelve month progress report deals with the chemical compatibility of semiconductor crystals grown in zero gravity. Specifically, it studies the chemical compatibility between TZM, a molybdenum alloy containing titanium and zirconium, and WC 103, a titanium alloy containing Niobium and Hafnium, and Gallium arsenide (GaAs) and Cadmium Zinc Tellurite (CdZnTe). Due to the health hazards involved, three approaches were used to study the chemical compatibility between the semiconductor and cartridge materials: reaction retort, thermogravimetric analysis, and bulk cylindrical cartridge containers. A scanning electron microscope with an energy dispersive X-ray analyzer was used to examine all samples after testing. The first conclusion drawn is that reaction rates with TZM were not nearly as great as they were with WC 103. Second, the total reaction between GaAs and WC 103 was almost twice that with TZM. Therefore, even though WC 103 is easier to fabricate, at least half of the cartridge thickness will be degraded if contact is made with one of the semiconductor materials leading to a loss of strength properties.

Wilcox, Roy C.↗

NASA NTRS1975

Hardness behavior of binary and ternary niobium alloys at 77 and 300 K

An investigation was conducted to determine the effects of alloy additions of zirconium, hafnium, molybdenum, tungsten, rhenium, ruthenium, osmium, rhodium, and iridium on the hardness of niobium. Both binary and ternary alloys were investigated by means of hardness tests at 77 and 300 K. Results showed that atomic size misfit plays a dominant role in controlling the hardness of binary niobium alloys. Alloy softening, which occurred at dilute solute additions, is most likely due to an extrinsic mechanism involving interaction between solute elements and interstitial impurities.

Stephens, J. R.↗

NASA NTRS1974

Hardness behavior of binary and ternary niobium alloys at 77 and 300 K

The effects of alloy additions of zirconium, hafnium, molybdenum, tungsten, rhenium, ruthenium, osmium, rhodium, and iridium on the hardness of niobium was determined. Both binary and ternary alloys were investigated by means of hardness tests at 77 K and 300 K. Results showed that atomic size misfit plays a dominant role in controlling hardness of binary niobium alloys. Alloy softening, which occurred at dilute solute additions, is most likely due to an extrinsic mechanism involving interaction between solute elements and interstitial impurities.

Stephens, J. R.↗

NASA NTRS1990

Electrochemical impedance spectroscopy of metal alloys in the space transportation system launch environment

AC impedance measurements were performed to investigate the corrosion resistance of 18 alloys under conditions similar to the Space Transportation System (STS) launch environment. The alloys were: (1) zirconium 702; (2) Hastelloy C-22, C-276, C-4, and B-2; (3) Inconel 600 and 825; (4) Ferralium 255; (5) Inco Alloy G-3; (6) 20Cb-3; (7) SS 904L, 304LN, 316L, 317L, and 304L; (8) ES 2205; and (9) Monel 400. AC impedance data were gathered for each alloy at various immersion times in 3.55 percent NaCl-0.1N HCl. Polarization resistance values were obtained for the Nyguist plots at each immersion time using the EQUIVALENT CIRCUIT software package available with the 388 electrochemical impedance software. Hastelloy C-22 showed the highest overall values for polarization resistance while Monel 400 and Inconel 600 had the lowest overall values. There was good general correlation between the corrosion performance of the alloys at the beach corrosion testing site, and the expected rate of corrosion as predicted based on the polarization resistance values obtained. The data indicate that electrochemical impedance spectroscopy can be used to predict the corrosion performance of metal alloys.

Calle, Luz↗

NASA NTRS1971

Design and fabrication of brayton cycle solar heat receiver

A detail design and fabrication of a solar heat receiver using lithium fluoride as the heat storage material was completed. A gas flow analysis was performed to achieve uniform flow distribution within overall pressure drop limitations. Structural analyses and allowable design criteria were developed for anticipated environments such as launch, pressure containment, and thermal cycling. A complete heat receiver assembly was fabricated almost entirely from the refractory alloy, niobium-1% zirconium.

Mendelson, I.↗

NASA NTRS1989

The interface in tungsten fiber reinforced niobium metal-matrix composites

The creep resistance of tungsten fiber reinforced niobium metal-matrix composites was evaluated. The interface region between the fiber and matrix was characterized by microhardness and electron probe microanalysis measurements which indicated that its properties were between those of fiber and matrix. However, the measured properties of the composite exceeded those calculated by the rule of mixtures even when the interface zone was assumed to retain all the strength of the fiber. The composite structure appeared to enhance the strengths of both the fibers and the matrix above what they exhibited in stand-alone tests. The effect of fiber orientation and matrix alloy composition on the fiber/matrix interface were also evaluated. Small alloying additions of zirconium and tungsten to the niobium matrix affected the creep resistance of the composites only slightly. A decrease in the creep resistance of the composite with increasing zirconium content in the matrix was ascribed to an increase in the diffusion rate of the fiber/matrix interdiffusion reaction, and a slight increase in the creep resistance of the composite was observed with an addition of 9 w percent tungsten to the matrix. In addition, Kirkendall void formation was observed at the fiber/matrix interface; the void distribution differed depending on the fiber orientation relative to the stress axis.

Grobstein, Toni L.↗

NASA NTRS1989

TEM studies of oxidized NiAl and Ni3Al cross sections

Cross sections of oxide scale/(Ni-Al) intermetallics were prepared by a new method and studied using primarily TEM. The cross sections were prepared by encasing an oxidized metal specimen sandwich in a low-melting-temperature zinc alloy. Observations of oxidized zirconium-doped beta-NiAl cross sections revealed crystallographic voids beneath an adherent Al2O3 scale. The oxide-metal interface was incoherent, but a high dislocation density in the metal near the interface suggested that a large tensile stress was induced by the attached oxide scale. A duplex Al2O3-NiAl2O4 scale formed on zirconium-doped and zirconium/boron-doped gamma-prime-Ni3Al alloys. Additional results are presented involving oxidation mechanisms and oxide-metal interface structures.

Doychak, J.↗

NASA NTRS1991

Investigation of welding and brazing of molybdenum and TZM alloy tubes

This effort involved investigating the welding and brazing techniques of molybdenum tubes to be used as cartridges in the crystal growth cartridge. Information is given in the form of charts and photomicrographs. It was found that the recrystallization temperature of molybdenum can be increased by alloying it with 0.5 percent titanium and 0.1 percent zirconium. Recrystallization temperatures for this alloy, known as TZM, become significant around 2500 F. A series of microhardness tests were run on samples of virgin and heat soaked TZM. The test results are given in tabular form. It was concluded that powder metallurgy TZM may be an acceptable cartridge material.

Lundblad, Wayne E.↗

NASA NTRS1991

The effect of copper, chromium, and zirconium on the microstructure and mechanical properties of Al-Zn-Mg-Cu alloys

The present study evaluates the effect of the systematic variation of copper, chromium, and zirconium contents on the microstructure and mechanical properties of a 7000-type aluminum alloy. Fracture toughness and tensile properties are evaluated for each alloy in both the peak aging, T8, and the overaging, T73, conditions. Results show that dimpled rupture essentially characterize the fracture process in these alloys. In the T8 condition, a significant loss of toughness is observed for alloys containing 2.5 pct Cu due to the increase in the quantity of Al-Cu-Mg-rich S-phase particles. An examination of T8 alloys at constant Cu levels shows that Zr-bearing alloys exhibit higher strength and toughness than the Cr-bearing alloys. In the T73 condition, Cr-bearing alloys are inherently tougher than Zr-bearing alloys. A void nucleation and growth mechanism accounts for the loss of toughness in these alloys with increasing copper content.

Wagner, John A.↗

NASA NTRS1985

Fatigue crack propagation of nickel-base superalloys at 650 deg C

The 650 C fatigue crack propagation behavior of two nickel-base superalloys, Rene 95 and Waspaloy, is studied with particular emphasis placed on understanding the roles of creep, environment, and two key grain boundary alloying additions, boron and zirconium. Comparison of air and vacuum data shows the air environment to be detrimental over a wide range of frequencies for both alloys. More in-depth analysis on Rene 95 shows at lower frequencies, such as 0.02 Hz, failure in air occurs by intergranular, environmentally-assisted creep crack growth, while at higher frequencies, up to 5.0 Hz, environmental interactions are still evident but creep effects are minimized. The effect of B and Zr in Waspaloy is found to be important where environmental and/or creep interactions are presented. In those instances, removal of B and Zr dramatically increases crack growth and it is therefore plausible that effective dilution of these elements may explain a previously observed trend in which crack growth rates increase with decreasing grain size.

Gayda, J.↗

NASA NTRS1986

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, J. R.↗

NASA NTRS1987

Thermal aging effects in refractory metal alloys

Stephens, Joseph R.↗