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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 NTRS1990

Materials for a Stirling engine heater head

Work done on the 25-kW advanced Stirling conversion system (ASCS) terrestrial solar program in establishing criteria and selecting materials for the engine heater head and heater tubes is described. Various mechanisms contributing to incompatibility between materials are identified and discussed. Large thermal gradients, coupled with requirements for long life (60,000 h at temperature) and a large number of heatup and cooldown cycles (20,000) drive the design from a structural standpoint. The pressurized cylinder is checked for creep rupture, localized yielding, reverse plasticity, creep and fatigue damage, and creep ratcheting, in addition to the basic requirements for bust and proof pressure. In general, creep rupture and creep and fatigue interaction are the dominant factors in the design. A wide range of materials for the heater head and tubes was evaluated. Factors involved in the assessment were strength and effect on engine efficiency, reliability, and cost. A preliminary selection of Inconel 713LC for the heater head is based on acceptable structural properties but driven mainly by low cost. The criteria for failure, the structural analysis, and the material characteristics with basis for selection are discussed.

Noble, J. E.↗
NASA NTRS1981

Elevated temperature mechanical properties and residual tensile properties of two cast superalloys and several nickel-base oxide dispersion strengthened alloys

The elevated temperature tensile, stress-rupture and creep properties and residual tensile properties after creep straining have been determined for two cast superalloys and several wrought Ni-16Cr-4Al-yttria oxide dispersion strengthened (ODS) alloys. The creep behavior of the ODS alloys is similar to that of previously studied ODS nickel alloys. In general, the longitudinal direction is stronger than the long transverse direction, and creep is at least partially due to a diffusional creep mechanism as dispersoid-free zones were observed after creep-rupture testing. The tensile properties of the nickel-base superalloy B-1900 and cobalt-base superalloy MAR-M509 are not degraded by prior elevated temperature creep straining (at least up to 1 pct) between 1144 and 1366 K. On the other hand, the room temperature tensile properties of ODS nickel-base alloys can be reduced by prior creep strains of 0.5 pct or less between 1144 and 1477 K, with the long transverse direction being more susceptible to degradation than the longitudinal direction.

Whittenberger, J. D.↗
NASA NTRS1987

Rupture testing for the quality control of electrodeposited copper interconnections in high-speed, high-density circuits

Printed Wiring Multilayer Board (PWMLB) structures for high speed, high density circuits are prone to failure due to the microcracking of electrolytic copper interconnections. The failure can occur in the foil that makes up the inner layer traces or in the plated through holes (PTH) deposit that forms the layer to layer interconnections. It is shown that there are some distinctive differences in the quality of Type E copper and that these differences can be detected before its use in a PWMLB. It is suggested that the strength of some Type E copper can be very low when the material is hot and that it is the use of this poor quality material in a PWMLB that results in PTH and inner layer microcracking. Since the PWMLB failure in question are induced by a thermal stress, and since the poorer grades of Type E materials used in these structures are susceptible to premature failure under thermal stress, the use of elevated temperature rupture and creep rupture testing is proposed as a means for screening copper foil, or its PTH equivalent, in order to eliminate the problem of Type E copper microcracking in advanced PWMLBs.

Zakraysek, Louis↗
NASA NTRS2010

Experimental Creep Life Assessment for the Advanced Stirling Convertor Heater Head

The United States Department of Energy is planning to develop the Advanced Stirling Radioisotope Generator (ASRG) for the National Aeronautics and Space Administration (NASA) for potential use on future space missions. The ASRG provides substantial efficiency and specific power improvements over radioisotope power systems of heritage designs. The ASRG would use General Purpose Heat Source modules as energy sources and the free-piston Advanced Stirling Convertor (ASC) to convert heat into electrical energy. Lockheed Martin Corporation of Valley Forge, Pennsylvania, is integrating the ASRG systems, and Sunpower, Inc., of Athens, Ohio, is designing and building the ASC. NASA Glenn Research Center of Cleveland, Ohio, manages the Sunpower contract and provides technology development in several areas for the ASC. One area is reliability assessment for the ASC heater head, a critical pressure vessel within which heat is converted into mechanical oscillation of a displacer piston. For high system efficiency, the ASC heater head operates at very high temperature (850 C) and therefore is fabricated from an advanced heat-resistant nickel-based superalloy Microcast MarM-247. Since use of MarM-247 in a thin-walled pressure vessel is atypical, much effort is required to assure that the system will operate reliably for its design life of 17 years. One life-limiting structural response for this application is creep; creep deformation is the accumulation of time-dependent inelastic strain under sustained loading over time. If allowed to progress, the deformation eventually results in creep rupture. Since creep material properties are not available in the open literature, a detailed creep life assessment of the ASC heater head effort is underway. This paper presents an overview of that creep life assessment approach, including the reliability-based creep criteria developed from coupon testing, and the associated heater head deterministic and probabilistic analyses. The approach also includes direct benchmark experimental creep assessment. This element provides high-fidelity creep testing of prototypical heater head test articles to investigate the relevant material issues and multiaxial stress state. Benchmark testing provides required data to evaluate the complex life assessment methodology and to validate that analysis. Results from current benchmark heater head tests and newly developed experimental methods are presented. In the concluding remarks, the test results are shown to compare favorably with the creep strain predictions and are the first experimental evidence for a robust ASC heater head creep life.

Krause, David L.↗
NASA NTRS2006

Predicting Lifetime of a Thermomechanically Loaded Component

NASALIFE is a computer program for predicting the lifetime, as affected by low cycle fatigue (LCF) and creep rupture, of a structural component subject to temporally varying, multiaxial thermomechanical loads. The component could be, for example, part of an aircraft turbine engine. Empirical data from LCF tests, creep rupture tests, and static tensile tests are used as references for predicting the number of missions the component can withstand under a given thermomechanical loading condition. The user prepares an input file containing the creep-rupture and cyclic-fatigue information, temperature-dependent material properties, and mission loading and control flags. The creep rupture information can be entered in tabular form as stress versus life or by means of parameters of the Larson-Miller equation. The program uses the Walker mean-stress model to adjust predicted life for ranges of the ratio between the maximum and minimum stresses. Data representing complex load cycles are reduced by the rainflow counting method. Miner's rule is utilized to combine the damage at different load levels. Finally, the program determines the total damage due to creep and combines it with the fatigue damage due to the cyclic loading and predicts the approximate number of missions a component can endure before failing.

Murthy, Pappu L. N.↗
NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗
NASA NTRS1998

Creep Life of Ceramic Components Using a Finite-Element-Based Integrated Design Program (CARES/CREEP)

The desirable properties of ceramics at high temperatures have generated interest in their use for structural application such as in advanced turbine engine systems. Design lives for such systems can exceed 10,000 hours. The long life requirement necessitates subjecting the components to relatively low stresses. The combination of high temperatures and low stresses typically places failure for monolithic ceramics in the creep regime. The objective of this paper is to present a design methodology for predicting the lifetimes of structural components subjected to creep rupture conditions. This methodology utilizes commercially available finite element packages and takes into account the time-varying creep strain distributions (stress relaxation). The creep life, of a component is discretized into short time steps, during which the stress and strain distributions are assumed constant. The damage is calculated for each time step based on a modified Monkman-Grant creep rupture criterion. Failure is assumed to occur when the normalized accumulated damage at any point in the component is greater than or equal to unity. The corresponding time will be the creep rupture life for that component. Examples are chosen to demonstrate the Ceramics Analysis and Reliability Evaluation of Structures/CREEP (CARES/CREEP) integrated design program, which is written for the ANSYS finite element package. Depending on the component size and loading conditions, it was found that in real structures one of two competing failure modes (creep or slow crack growth) will dominate. Applications to benchmark problems and engine components are included.

Powers, L. M.↗
NASA NTRS1998

Creep Life of Ceramic Components Using a Finite-Element-Based Integrated Design Program (CARES/CREEP)

The desirable properties of ceramics at high temperatures have generated interest in their use for structural applications such as in advanced turbine systems. Design lives for such systems can exceed 10,000 hours. The long life requirement necessitates subjecting the components to relatively low stresses. The combination of high temperatures and low stresses typically places failure for monolithic ceramics in the creep regime. The objective of this paper is to present a design methodology for predicting the lifetimes of structural components subjected to creep rupture conditions. This methodology utilized commercially available finite element packages and takes into account the time-varying creep strain distributions (stress relaxation). The creep life of a component is discretized into short time steps, during which the stress and strain distributions are assumed constant. The damage is calculated for each time step based on a modified Monkman-Grant creep rupture criterion. Failure is assumed to occur when the normalized accumulated damage at any point in the component is greater than or equal to unity. The corresponding time will be the creep rupture life for that component. Examples are chosen to demonstrate the CARES/CREEP (Ceramics Analysis and Reliability Evaluation of Structures/CREEP) integrated design programs, which is written for the ANSYS finite element package. Depending on the component size and loading conditions, it was found that in real structures one of two competing failure modes (creep or slow crack growth) will dominate. Applications to benechmark problems and engine components are included.

Gyekenyesi, J. P.↗
NASA NTRS1983

Environmental effects and viscoelastic behavior of laminated graphite/epoxy composites

Primarily because of the polymeric matrix, graphite/epoxy composites are viscoelastic materials which exhibit creep and delayed failures. Guided by the time-temperature superposition principle, the authors are developing accelerated characterization techniques to predict the long term compliance behavior and creep rupture strength of composite materials based on short term tests at elevated temperatures. The effect of a post-cure cycle on the compliance and creep rupture strength of composite materials is discussed. The Zhurkov type failure law is applied to experimental creep rupture data of a typical laminate and is shown to correlate the data. A beneficial mechanical strengthening effect is described which significantly affects the failure strengths of specimens which have been under creep loading for a period of time. This aging effect is reversible if the specimen is allowed to recover before being loaded to failure. Other environmental aspects of composite materials are also reviewed.

Dillard, D. A.↗
NASA NTRS1983

Correlation of Rupture Life, Creep Rate, and Microstructure for Type 304 Stainless Steel

The stress and temperature sensitivites of the rupture life and secondary creep rate were examined in detail for a single heat of type 304 stainless steel (9T2796). Assuming that the rupture life has a power law stress dependency, relatively small differences in the stress exponent were observed over a broad range of stress and temperature. In contrast, large changes were observed for equivalent parameter for secondary creep rate. As a result of these differences, the Monkman-Grant correlation was sensitive to stress and temperature below 650 C. Metallurgical studies based on light and transmission electron microscopy suggested that the temperature and stress sensitivities of secondary creep rate at temperatures below 650 C were related to features of the substructure not present at higher temperature. Specifically, the presence of a fine dislocation network stabilized by precipitates altered the stress and temperature sensitivities relative to what might be expected from high temperature studies.

Swindeman, R. W.↗
NASA NTRS1998

Annealing Effects on Creep and Rupture of Polycrystalline Alumina-Based Fibers

Continuous-length polycrystalline aluminum-oxide-based fibers are being considered as reinforcements for advanced high-temperature composite materials. For these fine-grained fibers, basic issues arise concerning grain growth and microstructural instability during composite fabrication and the resulting effects on the fiber's thermo-mechanical properties. To examine these issues, commercially available Nextel 610 (alumina) and Altex (alumina-silica) fibers were annealed at 1100 and 1300 C for up to 100 hr in air. Changes in fiber microstructure, fiber tensile creep, stress rupture, and bend stress relaxation (BSR) that occurred with annealing were then determined. BSR tests were also used to compare as-received and annealed fibers to other polycrystalline oxide fibers. Annealing was shown to have a significant effect, particularly on the Altex fiber, and caused it to have increased creep resistance.

Goldsby, J. C.↗
NASA NTRS1976

Influence of gaseous hydrogen on the mechanical properties of high temperature alloys

Tensile tests of six nickel-base and one cobalt-base alloy were conducted in 34.5 MN/sq m helium and hydrogen environments at temperatures from 297 K to 1,088 K. Mechanical properties tests of the nickel-base alloy MAR M-246 (Hf modified), in two cast conditions, were conducted in gaseous environments at temperatures from 297 K to 1,144 K and pressures from one atmosphere to 34.5 MN/sq m. The objective of this program was to obtain the mechanical properties of the various alloys proposed for use in space propulsion systems in a pure hydrogen environment at different temperatures and to compare with the mechanical properties in helium at the same conditions. All testing was conducted on solid specimens exposed to external gaseous pressure. Smooth and notched tensile properties were determined using ASTM tensile testing techniques, and creep-rupture life was determined using ASTM creep-rupture techniques. Low-cycle fatigue life was established by constant total strain and constant stress testing using smooth specimens and a closed-loop test machine.

Source record↗
NASA NTRS1997

Oxidation Embrittlement Observed in SiC/SiC Composites

As part of a comprehensive materials characterization program at the NASA Lewis Research Center, tensile creep-rupture tests were performed on a SiC-fiber-reinforced SiC-matrix composite. The results of these tests and subsequent analysis revealed an oxidation embrittlement phenomena that occurs readily at a discreet temperature range below the maximum use temperature. The graph shows rupture lives for a creep stress of 83 MPa as a function of temperature. Note that the rupture time is constant at an intermediate temperature range of 700 to 982 C. This graph also shows the failure location, as measured from the center of the specimen. Whereas for temperatures of 500 to 700 C, failure occurred in the specimen gage section; at higher temperatures, the failure location migrated toward the cooled grip ends. Although the results initially suggested that the test procedure was influencing the measured creep rupture lives and driving the failure location out of the gage section, subsequent experiments and thermal stress analyses verified the robustness of the test method employed.

Verrilli, Michael J.↗
NASA NTRS1979

The viscoelastic behavior of a composite in a thermal environment

A proposed method for the accelerated predictions of modulus and life times for time dependent polymer matrix composite laminates is presented. The method, based on the time temperature superposition principle and lamination theory, is described in detail. Unidirectional reciprocal of compliance master curves and the shift functions needed are presented and discussed. Master curves for arbitrarily oriented unidirectional laminates are predicted and compared with experimantal results obtained from master curves generated from 15 minute tests and with 25 hour tests. Good agreement is shown. Predicted 30 deg and 60 deg unidirectional strength master curves are presented and compared to results of creep rupture tests. Reasonable agreement is demonstrated. In addition, creep rupture results for a (90 deg + or - 60 deg/90 deg) sub 2s laminate are presented.

Morris, D. H.↗
NASA NTRS1959

Vacuum-Induction, Vacuum-Arc, and Air-Induction Melting of a Complex Heat-Resistant Alloy

The relative hot-workability and creep-rupture properties at 1600 F of a complex 55Ni-20Cr-15Co-4Mo-3Ti-3Al alloy were evaluated for vacuum-induction, vacuum-arc, and air-induction melting. A limited study of the role of oxygen and nitrogen and the structural effects in the alloy associated with the melting process was carried out. The results showed that the level of boron and/or zirconium was far more influential on properties than the melting method. Vacuum melting did reduce corner cracking and improve surface during hot-rolling. It also resulted in more uniform properties within heats. The creep-rupture properties were slightly superior in vacuum heats at low boron plus zirconium or in heats with zirconium. There was little advantage at high boron levels and air heats were superior at high levels of boron plus zirconium. Vacuum heats also had fewer oxide and carbonitride inclusions although this was a function of the opportunity for separation of the inclusions from high oxygen plus nitrogen heats. The removal of phosphorous by vacuum melting was not found to be related to properties. Oxygen plus nitrogen appeared to increase ductility in creep-rupture tests suggesting that vacuum melting removes unidentified elements detrimental to ductility. Oxides and carbonitrides in themselves did not initiate microcracks. Carbonitrides in the grain boundaries of air heats did initiate microcracks. The role of microcracking from this source and as a function of oxygen and nitrogen content was not clear. Oxygen and nitrogen did intensify corner cracking during hot-rolling but were not responsible for poor surface which resulted from rolling heats melted in air.

Decker, R. F.↗
NASA NTRS1998

Creep of Uncoated and Cu-Cr Coated NARloy-Z

Stress rupture creep tests were performed on uncoated and Cu-30vol%Cr coated NARloy-Z copper alloy specimens exposed to air at 482 C to 704 C. The results showed that creep failure in air of unprotected NARloy-Z was precipitated by brittle intergranular surface cracking produced by strain assisted grain boundary oxidation (SAGBO) which in turn caused early onset of tertiary creep. For the protected specimens, the Cu-Cr coating remained adherent throughout the tests and was effective in slowing down the rate of oxygen absorption, particularly at the higher temperatures, by formation of a continuous chromium oxide scale. As the result of reducing oxygen ingress, the coating prevented SAGBO initiated early creep failure, extended creep deformation and increased the creep rupture life of NARloy-Z over the entire 482 C to 704 C test temperature range.

Walter, R. J.↗