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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

High Temperature, Slow Strain Rate Forging of Advanced Disk Alloy ME3

The advanced disk alloy ME3 was designed in the HSR/EPM disk program to have extended durability at 1150 to 1250 F in large disks. This was achieved by designing a disk alloy and process producing balanced monotonic, cyclic, and time-dependent mechanical properties. combined with robust processing and manufacturing characteristics. The resulting baseline alloy, processing, and supersolvus heat treatment produces a uniform, relatively fine mean grain size of about ASTM 7, with as-large-as (ALA) grain size of about ASTM 3. There is a long term need for disks with higher rim temperature capabilities than 1250 F. This would allow higher compressor exit (T3) temperatures and allow the full utilization of advanced combustor and airfoil concepts under development. Several approaches are being studied that modify the processing and chemistry of ME3, to possibly improve high temperature properties. Promising approaches would be applied to subscale material, for screening the resulting mechanical properties at these high temperatures. n obvious path traditionally employed to improve the high temperature and time-dependent capabilities of disk alloys is to coarsen the grain size. A coarser grain size than ASTM 7 could potentially be achieved by varying the forging conditions and supersolvus heat treatment. The objective of this study was to perform forging and heat treatment experiments ("thermomechanical processing experiments") on small compression test specimens of the baseline ME3 composition, to identify a viable forging process allowing significantly coarser grain size targeted at ASTM 3-5, than that of the baseline, ASTM 7.

Gabb, Timothy P.↗
NASA NTRS2016

Engineering Design Tools for Shape Memory Alloy Actuators: CASMART Collaborative Best Practices and Case Studies

The primary goal of the Consortium for the Advancement of Shape Memory Alloy Research and Technology (CASMART) is to enable the design of revolutionary applications based on shape memory alloy (SMA) technology. In order to help realize this goal and reduce the development time and required experience for the fabrication of SMA actuation systems, several modeling tools have been developed for common actuator types and are discussed herein along with case studies, which highlight the capabilities and limitations of these tools. Due to their ability to sustain high stresses and recover large deformations, SMAs have many potential applications as reliable, lightweight, solid-state actuators. Their advantage over classical actuators can also be further improved when the actuator geometry is modified to fit the specific application. In this paper, three common actuator designs are studied: wires, which are lightweight, low-profile, and easily implemented; springs, which offer actuation strokes upwards of 200 at reduced mechanical loads; and torque tubes, which can provide large actuation forces in small volumes and develop a repeatable zero-load actuation response (known as the two-way shape memory effect). The modeling frameworks, which have been implemented in the design tools, are developed for each of these frequently used SMA actuator types. In order to demonstrate the versatility and flexibility of the presented design tools, as well as validate their modeling framework, several design challenges were completed. These case studies include the design and development of an active hinge for the deployment of a solar array or foldable space structure, an adaptive solar array deployment and positioning system, a passive air temperature controller for regulation flow temperatures inside of a jet engine, and a redesign of the Corvette active hatch, which allows for pressure equalization of the car interior. For each of the presented case studies, a prototype or proof-of-concept was fabricated and the experimental results and lessons learned are discussed. This analysis presents a collection of CASMART collaborative best practices in order to allow readers to utilize the available design tools and understand their modeling principles. These design tools, which are based on engineering models, can provide first-order optimal designs and are a basic and efficient method for either demonstrating design feasibility or refining design parameters. Although the design and integration of an SMA-based actuation system always requires application- and environment-specific engineering considerations, common modeling tools can significantly reduce the investment required for actuation system development and provide valuable engineering insight.

Design tools↗
NASA NTRS2004

Design and Control of a Proof-of-Concept Active Jet Engine Intake Using Shape Memory Alloy Actuators

The design and control of a novel proof-of-concept active jet engine intake using Nickel-Titanium (Ni-Ti or Nitinol) shape memory alloy (SMA) wire actuators is used to demonstrate the potential of an adaptive intake to improve the fuel efficiency of a jet engine. The Nitinol SMA material is selected for this research due to the material's ability to generate large strains of up to 5 percent for repeated operations, a high power-to-weight ratio, electrical resistive actuation, and easy fabrication into a variety of shapes. The proof-of-concept engine intake employs an overlapping leaf design arranged in a concentric configuration. Each leaf is mounted on a supporting bar that rotates upon actuation by SMA wires electrical resistive heating. Feedback control is enabled through the use of a laser range sensor to detect the movement of a leaf and determine the radius of the intake area. Due to the hysteresis behavior inherent in SMAs, a nonlinear robust controller is used to direct the SMA wire actuation. The controller design utilizes the sliding-mode approach to compensate for the nonlinearities associated with the SMA actuator. Feedback control experiments conducted on a fabricated proof-of-concept model have demonstrated the capability to precisely control the intake area and achieve up to a 25 percent reduction in intake area. The experiments demonstrate the feasibility of engine intake area control using the proposed design.

Song, Gangbing↗
NASA NTRS1996

New Theoretical Technique Developed for Predicting the Stability of Alloys

When alloys are being designed for aeronautical and other applications, a substantial experimental effort is necessary to make incremental changes in the desired alloy properties. A scheme to narrow the field to the most promising candidates would substantially reduce the high cost of this experimental screening. Such a method for determining alloy properties, called the BFS (Bozzolo, Ferrante, and Smith) method, has been developed at the NASA Lewis Research Center. This method was used to calculate the thermal stability and mechanical strength of 200 alloys of Ni3Al, with Cu and Au impurities forming ternary and quaternary compounds. With recent advances in the method, almost any metallic impurity and crystal structure can be addressed. In addition, thermal effects can be addressed with Monte Carlo techniques. At present, an experimental program is in progress to verify these results. The method identified a small number of the most promising candidates from the 200 alloys with the largest negative heat of formation and the highest bulk modulus. This calculation required only 5 min of CPU time on a VAX computer. It is clear that semi-empirical methods have achieved the level of development and reliability to warrant examining this new approach to the problem of alloy design. The present work was meant to demonstrate, perhaps in a rather simple way, this power. This type of application of atomistic simulation methods can narrow the gap and improve the feedback between theoretical predictions and laboratory experimentation.

Source record↗
NASA NTRSDate not supplied

In-Situ Alloying of GRCop-42 via Additive Manufacturing: Precipitate Analysis

GRCop-42, a Cu-4at% Cr-2at% Nb alloy, was designed as a high temperature, high strength, high heat flux material for rocket engine combustion chamber liners by NASA Glenn Research Center. In situ alloying of GRCop-42 (ISGRCop-42) using powder bed fusion (PBF) additive manufacturing (AM) takes elemental powders of Cu, Cr, and Nb to be introduced into the PBF environment and develop the GRCop alloy while simultaneously building an AM component. Elemental powders were milled together prior to printing in an effort to facilitate the alloying process. Success of the in situ alloying process may provide lower cost, faster lead times, alloying optimization, and more design freedom in the development of regeneratively-cooled rocket propulsion systems. Evaluation of the ISGRCop-42 was conducted using a phase extraction procedure to isolate the Cr2Nb precipitates from the pure Cu matrix. The isolated precipitates were then examined using x-ray powder diffraction (XRD), scanning electron microscopy (SEM), and energy dispersion spectroscopy (EDS). It was found that ISGRCop-42 successfully and repeatedly formed Cr2Nb at a yield as high as 89% of potential Cr2Nb. Further, it was identified that the preparation of the powder was the most influential factor in alloying success, and the second most influential factor was the laser power.

In Situ alloying↗
NASA NTRS2019

Bimetallic Channel Wall Nozzle Development and Hot-Fire Testing Using Additively Manufactured Laser Wire Direct Closeout Technology

NASA has been developing and advancing regeneratively-cooled channel wall nozzle technology for liquid rocket engines to reduce cost and schedules associated with fabrication. One of the primary methods being advanced is Laser Wire Direct Closeout (LWDC). LWDC was developed to provide an additively manufactured laser deposited closeout of the coolant channels that also forms the structural jacket in-situ. This technique has been previously demonstrated through process development and hot-fire testing on a series of subscale nozzles at NASA Marshall Space Flight Center. The hot-fire test articles were fabricated using monolithic alloys to simplify the fabrication process. Ongoing research is being conducted to further expand use of this process for increased scale and bimetallic or multi-alloy options. The use of multi-alloys is desired to fully optimize the combination of materials in the radial and axial directions to reduce overall weight of the nozzle and allow for higher thermal and structural margins on the channel wall nozzle. NASA recently completed process development and hot-fire testing of a series of channel wall nozzles that incorporate a copper-alloy as the hotwall liner material and a superalloy and combination thereof for the structural jacket using the LWDC technique. The fabrication process was further advanced by using a multi-alloy axial joint using explosive bonding integrating a copper-alloy at the forward end of the nozzle hotwall and a stainless-alloy for the remaining length. A third alloy was then used for the channel closeout using the LWDC process. This paper will describe the process development using the LWDC process for channel closeout utilizing the multi-alloys, hardware design and results from hot-fire testing on subscale multi-alloy LWDC channel cooled nozzles.

Gradl, Paul↗
NASA NTRS2024

ECI Final Report: Closing of Critical Technology Gaps for Rotating Detonation Rocket Engines

NASA has successfully fired several configurations of a dual regenerative 10K lbf class Rotating Detonation Rocket Engines using cryogenic liquid methane, liquid hydrogen, and RP-1 as fuel and liquid or gaseous oxygen as the oxidizer. In addition, 3 hot fire test phases were conducted to evaluate parametrically varying combustor geometries using a subscale 500-1K lbf class thruster RDRE. Several studies were successfully completed to evaluate the impacts of contraction ratio, annulus L’, heat transfer through calorimetry, and varying injector designs. Laser powder bed fusion GRCop-42, GRX-810, and C-103 alloys were used for the outer bodies, inner bodies, nozzles, and injector variations. The development of RDRE technology is only now possible with additive manufacturing techniques and these specialized alloys. Critical design parameters, design rules of thumb, and operability limitations have been identified. Major lessons learned in the development of critical components have also been documented. All critical technology gaps have been demonstrated at one scale or another and closed. A major finding of this work is that the combustion efficiency of the RDRE is far superior to that of the traditional liquid rocket engine requiring an order of magnitude lower chamber volume and residence time to react. Because of this, the design trade space opens up significantly. More compact chamber geometries are now possible with potential mass savings and significant length savings possible to flight geometries. In addition, the ceiling for the technology, in terms of Isp, has not yet been reached. It is likely that an additional ~10% better Isp over equivalent state-of-the-art combustion devices may be achieved over the next decade should the technology continue to be developed. This technology has been shown to be viable for near term infusion (2-5 years) into space missions and enable cost effective space access for US industry. This final report documents all major findings from this early career initiative (ECI) project and lays out what is needed post ECI.

Thomas Teasley↗
NASA NTRS1978

Design and fabrication of a super alloy thermal protection system

A lightweight metallic TPS was designed, and two test articles were fabricated, one from Haynes 188 and one from Rene 41. A baseline TPS concept, selected at the beginning of the program, consisted of a Haynes 25 corrugation-stiffened beaded skin surface panel, a specially designed support system, and an insulation system. By optimizing the structure for the design loads and by chem-milling to remove material not needed, the mass of the baseline surface panel was reduced 25%, and the mass of the support structure was reduced 50%. The insulation system mass was reduced 40% by using two types of insulation, each suited to its temperature range, and by eliminating a foul bag which encapsulated the baseline insulation system. These reductions resulted in an overall 35% reduction in mass of the Haynes 188 panel from the baseline Haynes 25 design. Similar reductions were achieved with the Rene 41 system.

Varisco, A.↗
NASA NTRS2002

Characterization of the Temperature Capabilities of Advanced Disk Alloy ME3

The successful development of an advanced powder metallurgy disk alloy, ME3, was initiated in the NASA High Speed Research/Enabling Propulsion Materials (HSR/EPM) Compressor/Turbine Disk program in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. This alloy was designed using statistical screening and optimization of composition and processing variables to have extended durability at 1200 F in large disks. Disks of this alloy were produced at the conclusion of the program using a realistic scaled-up disk shape and processing to enable demonstration of these properties. The objective of the Ultra-Efficient Engine Technologies disk program was to assess the mechanical properties of these ME3 disks as functions of temperature in order to estimate the maximum temperature capabilities of this advanced alloy. These disks were sectioned, machined into specimens, and extensively tested. Additional sub-scale disks and blanks were processed and selectively tested to explore the effects of several processing variations on mechanical properties. Results indicate the baseline ME3 alloy and process can produce 1300 to 1350 F temperature capabilities, dependent on detailed disk and engine design property requirements.

Gabb, Timothy P.↗
NASA NTRS1994

Characterization on defect solids

The purpose of this research has been to develop new semi-empirical techniques to describe ceramics, alloys, and metal/ceramic interfaces with applications in mind that support the materials aspects of the high speed civil transport program (HSCT). HSCT requires methods that aid in the design of alloys and ceramics for new high strength, high temperature applications. Current theoretical methods are not capable of carrying out this mission. Hence, new accurate and more efficient theoretical techniques are needed to facilitate the design of new materials and the examination of their properties. This program concentrated on modeling ceramics, but also dealt with alloy properties to a lesser degree. The primary accomplishment of this research was the development of a new equation of state (EOS) that models the energy/bond length relationship and includes terms that represent charge transfer between cations and anions. The new EOS has been used by researchers at the Naval Research Laboratory to develop a new semi-empirical method for calculating properties of ceramics and metal ceramic interfaces based on the embedded atom method. The results of the director's discretionary fund (DDF) research describing the binding energy relation was the enabling theoretical basis. Also the workers at Cleveland State and NASA Lewis have detailed an approach based on equivalent crystal theory as part of the DDF which is currently under development. In addition, initial results for using the Harris functional method have been developed. Finally, the techniques developed by us have proved useful for the study of high pressure properties of solids and have been used extensively by researchers in this field.

Schlosser, Herbert↗
NASA NTRS1945

Charts for the minimum-weight design of 24s-t aluminum-alloy flat compression panels with longitudinal z-section stiffeners

Design charts are developed for 24s-t aluminum-alloy flat compression panels with longitudinal z-section stiffeners. These charts make possible the design of the lightest panels of this type for a wide range of design requirements. Examples of the use of the charts are given and it is pointed out on the basis of these examples that, over a wide range of design conditions, the maintenance of buckle-free surfaces does not conflict with the achievement of high structural efficiency. The achievement of the maximum possible structural efficiency with 24s-t aluminum-alloy panels, however, requires closer stiffener spacings than those now in common use.

Schuette, Evan H↗
NASA NTRS2007

Pitting and Bending Fatigue Evaluations of a New Case-Carburized Gear Steel

The power density of a gearbox is an important consideration for many applications and is especially important for gearboxes used on aircraft. One approach to improving power density of gearing is to improve the steel properties by design of the alloy. The alloy tested in this work was designed to be case-carburized with surface hardness of Rockwell C66 after hardening. Test gear performance was evaluated using surface fatigue tests and single-tooth bending fatigue tests. The performance of gears made from the new alloy was compared to the performance of gears made from two alloys currently used for aviation gearing. The new alloy exhibited significantly better performance in surface fatigue testing, demonstrating the value of the improved properties in the case layer. However, the alloy exhibited lesser performance in single-tooth bending fatigue testing. The fracture toughness of the tested gears was insufficient for use in aircraft applications as judged by the behavior exhibited during the single tooth bending tests. This study quantified the performance of the new alloy and has provided guidance for the design and development of next generation gear steels.

Krantz, Timothy↗
NASA NTRS2003

A Comparison between Growth Morphology of "Eutectic" Cells/Dendrites and Single-Phase Cells/Dendrites

Directionally solidified (DS) intermetallic and ceramic-based eutectic alloys with an in-situ composite microstructure containing finely distributed, long aspect ratio, fiber, or plate reinforcements are being seriously examined for several advanced aero-propulsion applications. In designing these alloys, additional solutes need to be added to the base eutectic composition in order to improve heir high-temperature strength, and provide for adequate toughness and resistance to environmental degradation. Solute addition, however, promotes instability at the planar liquid-solid interface resulting in the formation of two-phase eutectic "colonies." Because morphology of eutectic colonies is very similar to the single-phase cells and dendrites, the stability analysis of Mullins and Sekerka has been extended to describe their formation. Onset of their formation shows a good agreement with this approach; however, unlike the single-phase cells and dendrites, there is limited examination of their growth speed dependence of spacing, morphology, and spatial distribution. The purpose of this study is to compare the growth speed dependence of the morphology, spacing, and spatial distribution of eutectic cells and dendrites with that for the single-phase cells and dendrites.

Tewari, S. N.↗
NASA NTRS1989

Design, development and applications of novel techniques for studying surface mechanical properties

Research is reviewed for the adhesion, friction, and micromechanical properties of materials and examples of the results presented. The ceramic and metallic materials studied include silicon carbide, aluminum oxide, and iron-base amorphous alloys. The design and operation of a torsion balance adapted for study of adhesion from the Cavendish balance are discussed first. The pull-off force (adhesion) and shear force (friction) required to break the interfacial junctions between contacting surfaces of the materials were examined at various temperatures in a vacuum. The surface chemistry of the materials was analyzed by X-ray photoelectron spectroscopy. Properties and environmental conditions of the surface regions which affect adhesion and friction-such as surface segregation, composition, crystal structure, surface chemistry, and temperature were also studied.

Miyoshi, Kazuhisa↗
NASA NTRS1995

A new Cu-8 Cr-4 Nb alloy for high temperature applications

Various applications exist where a high conductivity alloy with good strength and creep resistance are required. NASA LeRC has developed a Cu-8 at. percent Cr-4 at. percent Nb (Cu-8 Cr-4 Nb) alloy for these applications. The alloy is designed for use up to 700 C and shows exceptional strength, low cycle fatigue (LCF) resistance, and creep resistance. Cu-8 Cr-4 Nb also has a thermal conductivity of at least 72 percent that of pure Cu. Furthermore, the microstructure and mechanical properties of the alloy are very stable. In addition to the original application in combustion chambers, Cu-8 Cr-4 Nb shows promise for welding electrodes, brazing fixtures, and other applications requiring high conductivity and strength at elevated temperatures.

Ellis, D. L.↗
NASA NTRS1998

Modeling of Substitutional Site Preference in Ordered Intermetallic Alloys

We investigate the site substitution scheme of specific alloying elements in ordered compounds and the dependence of site occupancy on compound stoichiometry, alloy concentration. This basic knowledge, and the interactions with other alloying additions are necessary in order to predict and understand the effect of various alloying schemes on the physical properties of a material, its response to various temperature treatments, and the resulting mechanical properties. Many theoretical methods can provide useful but limited insight in this area, since most techniques suffer from constraints in the type of elements and the crystallographic structures that can be modeled. With this in mind, the Bozzolo-Ferrante-Smith (BFS) method for alloys was designed to overcome these limitations, with the intent of providing an useful tool for the theoretical prediction of fundamental properties and structure of complex systems. After a brief description of the BFS method, its use for the determination of site substitution schemes for individual as well as collective alloying additions to intermetallic systems is described, including results for the concentration dependence of the lattice parameter. Focusing on B2 NiAl, FeAl and CoAl alloys, the energetics of Si, Ti, V, Cr, Fe, Co, Ni, Cu, Zr, Nb, Mo, Ru, Hf, Ta and W alloying additions are surveyed. The effect of single additions as well as the result of two simultaneous additions, discussing the interaction between additions and their influence on site preference schemes is considered. Finally, the BFS analysis is extended to ternary L1(sub 2) (Heusler phase) alloys. A comparison between experimental and theoretical results for the limited number of cases for which experimental data is available is also included.

Bozzolo, Guillermo↗
NASA NTRS2000

Modeling of Ternary Element Site Substitution in NiAl

It is well recognized that ternary alloying additions can have a dramatic impact on the behavior of ordered intermetallic alloys such as nickel aluminides. Properties as diverse as yield strength, fracture strength, fracture mode, cyclic oxidation resistance, creep strength, and thermal and electrical diffusivity can change by orders of magnitude when a few percent or less of a ternary element is added. Yet our understanding of the resulting point defect structures and the simple site preferences of ternary alloying additions is poor because these are extremely difficult characteristics to determine. This disconnection between the understanding of the structure and properties in ordered alloys is at least in part responsible for the limited development and commercialization of these materials. Theoretical methods have provided useful but limited insight in this area, since most techniques suffer from constraints in the type of elements and the crystallographic structures that can be modeled. In an effort to overcome these limitations, the Bozzolo-Ferrante-Smith (BFS) method for alloys was designed. After a brief description of this approximate quantum mechanical approach, we use BFS to investigate the energetics of Si, Ti, V, Cr, Fe, Co, Cu, Zr, Nb, Mo, Ru, Hf, Ta and W additions to B2-ordered, stoichiometric NiAl. In addition to determining the site preference for these alloying additions over a range of compositions, we include results for the concentration dependence of the lattice parameter. In this introductory paper, we performed our analyses in the absence of constitutional and thermal vacancies for alloys of the form Ni50(Al,X)50. Where data exist, a comparison between experimental, theoretical, and BFS results is also included.

Bozzolo, Guillermo↗