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Nondestructive test methods are used for evaluating bond integrity of low-density polyurethane spray-on foam used as cryogenic insulation on aluminum alloy surfaces.
Hydrogen embrittlement of titanium alloy surface in hot salt corrosion cracking
A 0.61 x 1.22 m (2 x 4 ft) test panel was fabricated and delivered to the Langley Research Center for assessment of the thermal and structural features of the optimized panel design. The panel concept incorporated an aluminum alloy surface panel actively cooled by a network of discrete, parallel, redundant, counterflow passage interconnected with appropriate manifolding, and assembled by adhesive bonding. The cooled skin was stiffened with a mechanically fastened conventional substructure of stringers and frames. A 40 water/60 glycol solution was the coolant. Low pressure leak testing, radiography, holography and infrared scanning were applied at various stages of fabrication to assess integrity and uniformity. By nondestructively inspecting selected specimens which were subsequently tested to destruction, it was possible to refine inspection standards as applied to this cooled panel design.
The chemical mechanisms for sulfate formation from sodium chloride and sulfur trioxide, which is a product of jet fuel combustion was determined. Molten sodium sulfate leads to hot corrosion of the protective oxide layers on turbine blades. How yttrium dopants in nidkel-aluminum alloys used in turbine blades reduce the spalling rate of protective alumina films and enhance their adhesion was also determined. Two other fulfate mechanisms were deduced and structure of carbon monoxide on a clean chronium and clean platinum-titanium alloys surfaces was determined. All studies were by use of the atom superposition and electron delocalization molecular orbital (ASED-MO) theory. Seven studies were completed. Their titles and abstracts are given.
A large vacuum chamber (580 mm diameter) was fabricated from an aluminum alloy surface treated by a special process normally used on small chambers. The chamber was tested unbaked and baked at various temperatures, pressures, and holding periods. The chamber was filled with N2 gas, and the outgassing rate was measured after one hour. Then the ultimate pressure was measured. Outgassing rates for baked and unbaked groups were compared. It is concluded that the same surface treatment technique can be used on both large and small chambers produced by the same special extrusion process.
A CVD method was successfully developed to produce conversion coatings on aluminum alloys surfaces with reproducible results with a variety of precursors. A well defined protocol to prepare the precursor solutions formulated in a previous research was extended to other additives. It was demonstrated that solutions prepared following such a protocol could be used to systematically generate protective coatings onto aluminum surfaces. Experiments with a variety of formulations revealed that a refined deposition protocol yields reproducible conversion coatings of controlled composition. A preliminary correlation between solution formulations and successful precursors was derived. Coatings were tested for adhesion properties enhancement for commercial paints. A standard testing method was followed and clear trends were identified. Only one precursors was tested systematically. Anticipated work on other precursors should allow a better characterization of the effect of intermetallics on the production of conversion/protective coatings on metals and ceramics. The significance of this work was the practical demonstration that chemical vapor deposition (CVD) techniques can be used to systematically generate protective/conversion coating on non-ferrous surfaces. In order to become an effective approach to replace chromate-based pre- treatment processes, namely in the aerospace or automobile industry, the process parameters must be defined more precisely. Moreover, the feasibility of scale-up designs necessitates a more comprehensive characterization of the fluid flow, transport phenomena, and chemical kinetics interacting in the process. Kinetic characterization showed a significantly different effect of magnesium-based precursors when compared to iron-based precursors. Future work will concentrate on refining the process through computer simulations and further experimental studies on the effect of other transition metals to induce deposition of conversion/protective films on aluminum and other metallic substrates.
The surface tension and viscosity of quasicrystal-forming Ti-Zr-Ni alloys were measured over a range of temperature, including both stable and undercooled liquids by an Electrostatic Levitation (ESL) technique. ESL is a containerless technique which allows processing of samples without contact, greatly reducing contamination and increasing access to the metastable undercooled liquid. The measured viscosity is typical of glass-forming alloys of similar composition to the quasicrystal-forming alloys studied here, while the surface tension shows an anomaly at deep undercoolings.
A surface analytical examination of powder metallurgy processed Al-Li-Cu alloys was conducted. The oxide stringer particles often found in these alloys was characterized. Particle characterization is important to more fully understand their impact on the stress corrosion and fracture properties of the alloy. The techniques used were SIMS (Secondary Ion Mass Spectroscopy) and SAM (Scanning Auger Microscopy). The results indicate that the oxide stringer particles contain both Al and Li with relatively high Li content and the Li compounds may be associated with the stringer particles, thereby locally depleting the adjacent matrix of Li solute.
A surface analytical examination of powder metallurgy processed Al-Li-Cu alloys was conducted. The oxide stringer particles often found in these alloys are characterized. Particle characterization is important to more fully understand their impact on the stress corrosion and fracture properties of the alloy. The techniques used where SIMS (Secondary Ion Mass Spectroscopy) and SAM (Scanning Auger Microscopy). The results indicate that the oxide stringer particles contain both Al and LI with relatively high Li content and the Li compounds may be associated with the stringer particles, thereby locally depleting the adjacent matrix of Li solute.
Polyimide-silica hybrids composed of an organic precursor containing a novel phenylethynyl imide silane and an inorganic precursor were evaluated as an adhesion-promoting interphase between surface-treated titanium alloy and a phenylethynyl-containing imide adhesive. The phenylethynyl groups present in the organic precursor, either as a pendent or end group, can bond chemically with a phenylethynyl-containing imide adhesive during processing, while the silane groups of the organic precursor would react chemically with the inorganic precursor. In addition, the inorganic precursor is able to react with the titanium alloy to form a stable bond with the metal oxide. Bond strength and durability were evaluated by single lap shear tests at various conditions. Lap shear specimens exhibited predominantly cohesive failure after a 3-d water boil with 92% retention of the initial room temperature strength. Morphology and chemical composition of the hybrid interphase were investigated with scanning electron microscopy, X-ray photoelectron spectroscopy, and Auger electron spectroscopy, which revealed development of a silicon-gradient, hybrid structure between the metal substrate and the adhesive.
Corrosion studies of 2195 Al-Li and 2219 Al alloys have been conducted using the scanning reference electrode technique (SRET) and the polarization resistance (PR) technique. The SRET was used to study corrosion mechanisms, while corrosion rate measurements were studied with the PR technique. Plates of Al203 blasted, soda blasted and conversion coated 2219 Al were coated with Deft primer and the corrosion rates studied with the EIS technique. Results from all of these studies are presented.
Using BFS, a new semiempirical method for alloys, we study the surface structure of fcc ordered binary alloys in the Ll(sub 2) structure (Ni3Al and Cu3Au). We show that the surface energy is lowest for the mixed composition truncation of the low-index faces of such systems. Also, we present results for the interlayer relaxations for planes close to the surface, revealing different relaxations for atoms of different species producing a rippled surface layer.
The crack-closure and crack-growth characteristics of the titanium alloy Ti-6Al-4V were determined experimentally on surface-flawed plate specimens. Under cyclic loading from zero to tension, cracks deeper than 1 mm opened at approximately 50 percent of the maximum load. Cracks shallower than 1 mm opened at higher loads. The correlation between crack-growth rate and the total stress-intensity range showed a lower threshold behavior. This behavior was attributed to the high crack-opening loads at short cracks because the lower threshold was much less evident in correlations between the crack-growth rates and the effective stress-intensity range.
High-speed commercial aircraft require a surface treatment for titanium (Ti) alloy that is both environmentally safe and durable under the conditions of supersonic flight. A number of pretreatment procedures for Ti alloy requiring multi-stages have been developed to produce a stable surface. Among the stages are, degreasing, mechanical abrasion, chemical etching, and electrochemical anodizing. These treatments exhibit significant variations in their long-term stability, and the benefits of each step in these processes still remain unclear. In addition, chromium compounds are often used in many chemical treatments and these materials are detrimental to the environment. Recently, a chromium-free surface treatment for Ti alloy has been reported, though not designed for high temperature applications. In the present study, a simple surface treatment process developed at NASA/LaRC is reported, offering a high performance surface for a variety of applications. This novel surface treatment for Ti alloy is conventionally achieved by forming oxides on the surface with a two-step chemical process without mechanical abrasion. This acid-followed-by-base treatment was designed to be cost effective and relatively safe to use in a commercial application. In addition, it is chromium-free, and has been successfully used with a sol-gel coating to afford a strong adhesive bond after exposure to hot-wet environments. Phenylethynyl containing adhesives were used to evaluate this surface treatment with sol-gel solutions made of novel imide silanes developed at NASA/LaRC. Oxide layers developed by this process were controlled by immersion time and temperature and solution concentration. The morphology and chemical composition of the oxide layers were investigated using scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), and Auger electron spectroscopy (AES). Bond strengths made with this new treatment were evaluated using single lap shear tests.
The interaction of hydrogen at the surface of alpha-2 titanium aluminide alloys with Nb additions has been investigated with Auger electron spectroscopy (AES) and reflected electron energy loss (REELS) spectroscopy. The hydrogen was either adsorbed onto the alloy surface from the gas phase or it was pre-charged into the alloy forming an alpha-2 hydride. No effect of either adsorbed or absorbed hydrogen was observed in the Auger spectra. A shift in the bulk plasmon loss energy (observed with REELS) was measured for both conditions. The potential significance of these results in relation to hydrogen interactions in this alloy is discussed.
The surface regions of a DSNiCrAl alloy have been doped, by a pack diffusion process, with small amounts of Mn, Fe, or Co, and the effect of these dopants on the total normal emissivity of the scales produced by subsequent high temperature oxidation has been measured. While all three elements lead to a modest increase in emissivity, (up to 23% greater than the undoped alloy) only the change caused by manganese is thermally stable. However, this increased emissivity is within 85 percent of that of TDNiCr oxidized to form a chromia scale. The maganese-doped alloy is some 50 percent weaker than undoped DSNiCrAl after the doping treatment, and approximately 30 percent weaker after oxidation.
Thermoelectric power and Fermi surface in silver-gold alloys
The surface tension, viscosity, density, and thermal expansion of Ti-Zr-Ni alloys were measured for a number of compositions by electrostatic levitation methods. Containerless methods greatly reduce heterogeneous nucleation, increasing access to the undercooled liquid regime at finite cooling rates. The density and thermal expansion are measured optically, while the surface tension and viscosity are measured by the oscillating drop method. The measured alloys include compositions which form a metastable quasicrystal phase from the undercooled liquid, and alloys close to the composition of several multi-component bulk metallic glass-forming alloys. Measurements of surface tension show behavior typical of transition metals at high temperature, but a sudden decrease in the deeply undercooled liquid for alloys near the quasicrystal-forming composition range, but not for compositions which form the solid-solution phase first.