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NASA NTRS1993

A combined experimental and finite element study to predict the failure mechanisms in SiC coated carbon/carbon composites at room and elevated temperatures under flexural loading

Response of quasi-isotropic laminates of SiC coated Carbon/Carbon (C/C) composites have been investigated under flexural loading at various temperatures. Variation of load-deflection behavior with temperatures are studied. Increase in flexural strength and stiffness are observed with the rise in temperature. Extensive analyses through Optical Microscope (OM) and Non-Destructive Evaluation (NDE) have been performed to understand the failure mechanisms. Damage zone is found only within the neighborhood of the loading plane. Isoparametric layered shell elements developed on the basis of the first order shear deformation theory have been used to model the thin laminates of C/C under flexural loading. Large deformation behavior has been considered in the finite element analysis to account for the non-linearities encountered during the actual test. Data generated using finite element analysis are presented to corroborate the experimental findings, and a comparison in respect of displacement and stress-strain behavior are given to check the accuracy of the finite element analysis. Reasonable correlation between the experimental and finite element results have been established.

Mahfuz, Hassan↗

NASA NTRS2003

Strength Differential Measured in Inconel 718: Effects of Hydrostatic Pressure Studied

Aeropropulsion components, such as disks, blades, and shafts, are commonly subjected to multiaxial stress states at elevated temperatures. Experimental results from loadings as complex as those experienced in service are needed to help guide the development of accurate viscoplastic, multiaxial deformation models that can be used to improve the design of these components. During a recent study on multiaxial deformation (ref. 1) on a common aerospace material, Inconel 718, it was shown that the material in the aged state exhibits a strength differential effect (SDE), whereby the uniaxial compressive yield and subsequent flow behavior are significantly higher than those in uniaxial tension. Thus, this material cannot be described by a standard von Mises yield formulation. There have been other formulations postulated (ref. 2) that involve other combinations of the stress invariants, including the effect of hydrostatic stress. The question remained as to which invariants are necessary in the flow model. To capture the physical mechanisms occurring during deformation and reflect them in the plasticity formulation, researchers examined the flow of Inconel 718 under various amounts of hydrostatic stress to determine whether or not hydrostatic stress is needed in the formulation. Under NASA Grant NCC3-464, monitored by the NASA Glenn Research Center, a series of tensile tests were conducted at Case Western Reserve University on aged (precipitation hardened) Inconel 718 at 650 C and with superimposed hydrostatic pressure. Dogbone shaped tensile specimens (3-mm-diameter gauge by 16-mm gauge length) and cylindrical compression specimens (3-mm-diameter gauge by 6-mm gauge length) were strain gauged and loaded in a high-pressure testing apparatus. Hydrostatic pressures were obtained with argon and ranged from 210 to 630 MPa. The aged Inconel 718 showed a pronounced difference in the tension and compression yield strength (i.e., an SDE), as previously observed. Also, there were no significant effects of hydrostatic pressure on either the tensile and compressive yield strength (see the graph) or on the magnitude of the SDE. This behavior is not consistent with the pressure-dependent theory of the SDE, which postulates that the SDE is associated with pressure-dependent and/or internal friction dependent deformation associated with non-Schmid effects at the crystal level (refs. 3 and 4). Flow in Inconel 718 appears to be independent of hydrostatic pressure, suggesting that this invariant may be removed from the phenomenological constitutive model. As part of an ongoing effort to develop advanced constitutive models, Glenn s Life Prediction Branch coordinated this work with that of research on the multiaxial deformation behavior of Inconel 718 being conducted at Pennsylvania State University under NASA Grant NCC597.

Lewandowski, John J.↗

DOE OSTI2020

Nanoscale serration characteristics of additively manufactured superalloys

Structural elements made of nickel-based superalloys usually operate at high temperatures. Many surface failure mechanisms such as creep, fatigue, fretting fatigue, corrosion, and stress corrosion cracking start from the surface. Thus, studying the surface mechanical properties and deformation behavior of materials is vital in order to draw a correlation between the surface properties and failures. Herein, a nanoindentation technique was implemented to characterize surface properties of a widely used additively manufactured (AM) superalloy, i.e., Inconel 625. The specimens were tested in a range of temperatures in a vacuum chamber. Serrated plastic flow characterized by pop-in events during nanoindentation, known as Portevin-Le Chatelier (PLC) effect, was observed in all three tested elevated temperatures. This phenomenon depicts itself as bursts of plasticity in the loading section of the load-displacement curves. These bursts were studied comprehensively to explore incipient plasticity. Hertzian contact mechanics were implemented to extract the maximum shear stress beneath the indenter from the pop-in loads. The results show that the initial pop-in load increases as the temperature increases. The average initial pop-in load increases by almost four times from 300 °C to 650 °C. This was attributed to the formation of strengthening precipitates. The average size of the serrations and the magnitude of dislocation nucleation increase from 300 °C to 500 °C and decrease from 500 °C to 650 °C. Finally, the serrations are attributed to the dislocation generation and movement as well as their interaction with the solute atoms and precipitates.

36 MATERIALS SCIENCE↗

NASA NTRS1989

High-temperature ordered intermetallic alloys III; Proceedings of the Third Symposium, Boston, MA, Nov. 29-Dec. 1, 1988

The present conference on high-temperature ordered intermetallic alloys discusses alloy theory and phase stability, defects and microstructures, mechanical behavior, alloy design and material processing, multiphase and composite materials, nickel aluminides, titanium aluminides, and other ordered intermetallics. Attention is given to compositional effects on processing and properties of nickel aluminides, dynamic compaction and hot-isostatic-pressing of nickel aluminides, improvement of elevated-temperature material properties in Ni3Al, the effect of microalloying B on the high-temperature mechanical properties of Ti3Al, the effects of structure on creep of Ti-53.4 mol pct Al intermetallics, the deformation microstructure in Ni3Si polycrystals strained over the range of temperature of flow stress anomaly, and the microstructure and mechanical properties of dual phase alloys consisting of the intermetallic phases.

Liu, C. T.↗

NASA NTRS2001

Damage Assessment of Creep Tested and Thermally Aged Metallic Alloys Using Acousto-Ultrasonics

In recent years emphasis has been placed on the early detection of material changes experienced in turbine powerplant components. During the scheduled overhaul of a turbine, the current techniques of examination of various hot section components aim to find flaws such as cracks, wear, and erosion, as well as excessive deformations. Thus far, these localized damage modes have been detected with satisfactory results. However, the techniques used to find these flaws provide no information on life until the flaws are actually detected. Major improvements in damage assessment, safety, as well as more accurate life prediction could be achieved if nondestructive evaluation (NDE) techniques could be utilized to sense material changes that occur prior to the localized defects mentioned. Because of elevated temperatures and excessive stresses, turbine components may experience creep behavior. As a result, it is desirable to monitor and access the current condition of such components. Research at the NASA Glenn Research Center involves developing and utilizing an NDE technique that discloses distributed material changes that occur prior to the localized damage detected by the current methods of inspection. In a recent study, creep processes in a nickel-base alloy were the life-limiting condition of interest, and the NDE technique was acousto-ultrasonics (AU). AU is an NDE technique that utilizes two ultrasonic transducers to interrogate the condition of a test specimen. The sending transducer introduces an ultrasonic pulse at a point on the surface of the specimen while a receiving transducer detects the signal after it has passed through the material. The goal of the method is to correlate certain parameters of the detected waveform to characteristics of the material between the two transducers. Here, the waveform parameter of interest is the attenuation due to internal damping for which information is being garnered from the frequency domain. The parameters utilized to indirectly quantify the attenuation are the ultrasonic decay rate as well as various moments of the frequency power spectrum. A new, user-friendly, graphical interface AU system was developed at NASA Glenn. This system is an all-inclusive, multifunction system that controls the sending and receiving ultrasonic transducers as well as all posttest signal analysis. The system's postprocessing software calculates the multiple parameters used to study the material of interest.

Gyekenyesi, Andrew L.↗

DOE OSTI2023

Strengthening mechanisms, hardening/softening behavior, and microstructure evolution in an LPSO magnesium alloy at elevated temperatures

Here, rapid degradation of the mechanical properties of conventional Mg alloys with temperature precludes their wide application in industry. The LPSO (long period stacking ordered) Mg alloys, on the other hand, show considerable potential to achieve excellent high-temperature mechanical performance. In this study, a Mg-5.1Y-2.4Zn (wt.%) extrusion alloy with the microstructure comprising of α-Mg matrix and LPSO phase was prepared. It is shown that the yield strength of the alloy at 200 °C retained ~83% of the yield strength of 198 MPa at room temperature (RT). Importantly, the ductility also improved, owing to the increased non-basal slip activities at elevated temperatures. In contrast to RT and 200 °C, the alloy exhibited softening tensile behavior with an apparent loss of yield strength at 300 °C. In-situ lattice strain analysis revealed that load transfer from α-Mg to LPSO remains effective at temperatures up to 200 °C, governing the high yield strength of the alloy. The post-mortem analysis by means of electron microscopy confirmed that the LPSO phase is structurally stable at 200 °C. In particular, the high strain hardenability is rationalized by the sandwiched LPSO structures together with stacking faults serving as effective obstacles to the motion of non-basal dislocations. The load transfer effect disappears at the temperature of 300 °C, resulting in the fast deterioration of strength of the alloy. The cracking of the LPSO phase along with the recrystallizing of α-Mg grains were found to be the main causes for the softening behavior of the alloy at 300 °C.

36 MATERIALS SCIENCE↗

NASA NTRS1990

Analytical and experimental studies on creep behavior of polymeric matrix composites

The creep behavior of graphite/epoxy composites is studied both analytically and experimentally. In the analytical study, a special finite element procedure was developed for the accurate and efficient analysis of creep response in anisotropic materials. This procedure was used to study the stress and strain distributions and histories in composite laminates containing circular holes. In the experimental study, creep tests were performed to investigate the time-dependent response of graphite/epoxy composites at elevated temperature. The moire interferometry technique was employed to determine the deformation histories in notched composites. The experimental results were compared with the analytical predictions and good agreement was observed.

Lin, K. Y.↗

DOE OSTI2025

Modeling low cycle fatigue (LCF) of additively manufactured Hastelloy X using An accelerated crystal plasticity fatigue damage model

This paper presents a microstructure-based model for low cycle fatigue (LCF) behavior and life of Nickel-based alloy Hastelloy X manufactured using laser-powder bed fusion (L-PBF) additive manufacturing (AM). AM Hastelloy X, a solution-strengthened alloy, is tested at elevated temperature under fully reversed LCF conditions at different strain levels. A generalized plane strain finite element model is generated from electron backscatter diffraction (EBSD) characterization. The constitutive behavior of the material under fatigue is modeled using crystal plasticity and calibrated with both monotonic tensile and cyclic stress–strain data. The fatigue micro-crack initiation and propagation in the microstructure is modeled using a modified Chaboche fatigue damage model. An embedded boundary condition with a homogenous medium is used to apply the cyclic deformation and prevent numerically introduced over-constraints during fatigue simulation. A ‘cycle-jump’ method is used to accelerate the fatigue simulation and reduce the computational cost. The simulation results are compared to LCF experiments, showing satisfactory matches in cyclic stress behavior and number of cycles to macro-crack initiation for all applied strain ranges. In addition, the model illustrates the potential for quantifying microscale fatigue life impacting factors such as microstructure and surface roughness, which is needed to accurately quantify the reliability of AM components in service.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Kink bands promote exceptional fracture resistance in a NbTaTiHf refractory medium-entropy alloy

Single-phase body-centered cubic (bcc) refractory medium- or high-entropy alloys can retain compressive strength at elevated temperatures but suffer from extremely low tensile ductility and fracture toughness. We examined the strength and fracture toughness of a bcc refractory alloy, NbTaTiHf, from 77 to 1473 kelvin. This alloy’s behavior differed from that of comparable systems by having fracture toughness over 253 MPa·m 1/2 , which we attribute to a dynamic competition between screw and edge dislocations in controlling the plasticity at a crack tip. Whereas the glide and intersection of screw and mixed dislocations promotes strain hardening controlling uniform deformation, the coordinated slip of <111> edge dislocations with {110} and {112} glide planes prolongs nonuniform strain through formation of kink bands. These bands suppress strain hardening by reorienting microscale bands of the crystal along directions of higher resolved shear stress and continually nucleate to accommodate localized strain and distribute damage away from a crack tip.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Understanding the deformation mechanisms in Ni-based superalloys with using crystal plasticity finite element method

Nl-based superalloy is considered as a good candidate due to its excellent resistance to elevated temperature deformation for long term period application. Understanding the deformation and failure mechanisms of Ni-Based superalloys is very helpful for providing design guidelines for processing Ni-based superalloys. Experimental characterization indicates that the deformation mechanisms of Ni based superalloy is strongly microstructure dependent. Besides, damage transform from the void nucleation to the macro cracks by voids growth leading to the failure of the Ni-based superalloys are also showing strong microstructure sensitivity. Therefore, this work focuses on the prediction and comprehension of the deformation and void growth behavior in Ni based superalloy at different working conditions via crystal plasticity finite element modeling and simulation. Physically based crystal plasticity frameworks were developed for newly Ni- based superalloy Haynes 282. It was found that dislocation shearing through the precipitates were acting as the main contributor to the strength of Haynes 282 at room temperature and 815°C. Our analysis of the creeping behavior of Haynes 282 exhibited that resistance of general climb replaced by the resistance induced by the deposited climb dislocation density. In addition, in the study of void growth behavior, our simulation results demonstrated that as the main loading axis perpendicular to the grain boundary (GB), voids grow more slowly on tilt GBs in bicrystals than those in single and bicrystals with twist GBs. And tilt GBs would promote the void grow into irregular shape.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Load shuffling during creep deformation of an additively manufactured AlCuMnZr alloy

Here, the high-temperature deformation behavior of an additively manufactured Al-Cu-Mn-Zr alloy is evaluated in the as-fabricated and heat-treated states using traditional ex-situ and in-situ neutron diffraction creep experiments performed at 300 °C. The dominant reinforcement phase in the alloy, θ-Al 2 Cu, despite its high volume fraction of ~10%, does not provide load transfer strengthening during creep deformation. Instead, the lattice strain evolution suggests a new mechanism we term “load shuffling” wherein the initial load is transferred away from precipitate-free zones along the grain boundaries where most of the θ-Al 2 Cu particles are located to precipitate-strengthened grain interiors. Notwithstanding the lack of load transfer strengthening, the as-fabricated AM Al-Cu-Mn-Zr alloy still possesses improved creep resistance at 300 °C relative to a cast alloy with similar composition. The proposed load shuffling mechanism explains the lack of observed L1 2 -Al 3 Zr strengthening at 300 °C and helps identify several strategies for improvement of elevated-temperature mechanical response of AM Al alloys.

36 MATERIALS SCIENCE↗

NASA NTRS2001

Fretting Wear of Ti-48Al-2Cr-2Nb

An investigation was conducted to examine the wear behavior of gamma titanium aluminide (Ti-48Al-2Cr-2Nb in atomic percent) in contact with a typical nickel-base superalloy under repeated microscopic vibratory motion in air at temperatures from 296-823 K. The surface damage observed on the interacting surfaces of both Ti-48Al-2Cr-2Nb and superalloy consisted of fracture pits, oxides, metallic debris, scratches, craters, plastic deformation, and cracks. The Ti-48Al-2Cr-2Nb transferred to the superalloy at all fretting conditions and caused scuffing or galling. The increasing rate of oxidation at elevated temperatures led to a drop in Ti-48Al-2Cr-2Nb wear at 473 K. Mild oxidative wear was observed at 473 K. However, fretting wear increased as the temperature was increased from 473-823 K. At 723 and 823 K, oxide disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Ti-48Al-2Cr-2Nb wear generally decreased with increasing fretting frequency. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals. Keywords

Miyoshi, Kazuhisa↗

NASA NTRS2000

Time-Dependent Reversible-Irreversible Deformation Threshold Determined Explicitly by Experimental Technique

Structural materials for the design of advanced aeropropulsion components are usually subject to loading under elevated temperatures, where a material's viscosity (resistance to flow) is greatly reduced in comparison to its viscosity under low-temperature conditions. As a result, the propensity for the material to exhibit time-dependent deformation is significantly enhanced, even when loading is limited to a quasi-linear stress-strain regime as an effort to avoid permanent (irreversible) nonlinear deformation. An understanding and assessment of such time-dependent effects in the context of combined reversible and irreversible deformation is critical to the development of constitutive models that can accurately predict the general hereditary behavior of material deformation. To this end, researchers at the NASA Glenn Research Center at Lewis Field developed a unique experimental technique that identifies the existence of and explicitly determines a threshold stress k, below which the time-dependent material deformation is wholly reversible, and above which irreversible deformation is incurred. This technique is unique in the sense that it allows, for the first time, an objective, explicit, experimental measurement of k. The underlying concept for the experiment is based on the assumption that the material s time-dependent reversible response is invariable, even in the presence of irreversible deformation.

Castelli, Michael G.↗

DOE OSTI2023

Microstructure and Temperature Dependent Indentation Response of Additively Manufactured Precipitation-Strengthened Al 0.3 Ti 0.2 Co 0.7 CrFeNi 1.7 High Entropy Alloy

The temperature-dependent [from room temperature (RT) to 500°C] nanoindentation behavior of a precipitation-strengthened Al 0.3 Ti 0.2 Co 0.7 CrFeNi 1.7 high-entropy alloy (HEA) processed via two different additive manufacturing (AM) techniques was investigated in the as-deposited and annealed conditions. The hierarchically heterogeneous microstructures were achieved via simple one-step annealing treatments, exploiting the residual stresses in the AM-processed HEA to partially recrystallize the microstructure, performed remarkably better than the nearly homogeneous microstructures in the as-deposited state. Further, the one-step annealed conditions revealed < 6.6% reduction in hardness values at 500°C compared to RT, while the as-deposited conditions showed a > 18% reduction in the hardness. The one-step annealed conditions also exhibited significantly higher hardness than the as-deposited conditions owing to their L1 2 -strengthened FCC microstructures. Furthermore, serrated yielding or the Portevin-Le Chatlier effect indicative of microstructural instability was observed during nanoindentation deformation (at 500°C) for the as-deposited conditions but not for the one-step annealed conditions. This, therefore, signifies the robustness of the hierarchically heterogeneous microstructures at elevated temperatures presenting a strong avenue for tuning the HEAs for future nuclear reactor applications.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Effect of N 2 - and CO 2 -containing shielding gases on composition modification and carbonitride precipitation in wire arc additive manufactured grade 91 steel

Additive manufacturing (AM) represents a promising technique to fabricate metallic alloys with greater control of the resulting material features as compared to traditional manufacturing routes. Recently, there is greater interest in AM research on 9 wt% Cr ferritic/martensitic (F/M) steels, which are commonly studied for use in the nuclear energy industry. This work aims to prove that wire arc AM can manufacture F/M steels with adequate mechanical properties in multiple processing atmospheres and aims to study how shielding gas composition can be leveraged during fabrication to induce specific precipitation pathways. The effect of shielding gas composition on MX (M=Nb and/or V, Xdouble bondC and/or N) carbonitride precipitation in a 9 wt% Cr ferritic/martensitic (F/M) steel alloy known as Grade 91 was studied using N 2 and CO 2 gas additions to an inert Ar shielding gas atmosphere during wire arc AM. The N and C atoms present in the processing atmospheres were absorbed into the melt pools during fabrication. Due to their differing affinities for precipitate-forming reactions, the varying levels of C and N between the samples contributed to differences in final carbonitride composition and morphologies. Such precipitate behavior is of interest as carbonitrides have been shown to contribute to increased mechanical performance. This increased performance was studied via electron microscopy and tested for strength, ductility, and fracture properties.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Process control-enabled mitigation of microstructural and plastic heterogeneities in additively manufactured Grade 91 steel

Synergizing wire arc-directed energy deposition (WA-DED) additive manufacturing (AM) with particle-strengthened creep strength-enhanced ferritic (CSEF) steels enables fabrication and repair of critical power-plant components. Investigations focused on fusion-welded particle-strengthened CSEF steels, such as Grade 91 steel, have linked microstructurally heterogeneous regions—forming due to heat affected zones (HAZ)—with premature failure during elevated temperature service. Fusion-based AM, including WA-DED, likewise generates microstructurally and plastically heterogeneous regions due to spatiotemporally varying thermokinetics during deposition. However, works investigating such microstructural heterogeneities, their implications for mechanical behavior, and strategies to mitigate their formation remain scarce. This work identifies microstructurally and plastically heterogeneous regions within the WA-DED-processed Grade 91 steel. Spatial microhardness variations in the as-fabricated specimen correlate with the variation in the attributes of grain, martensitic microstructure, and precipitates across the fusion zone and HAZ. Digital image correlation-enabled tensile tests performed at 500 °C revealed pronounced deformation localization and a wave-like strain distribution, with wavelength close to the melt pool depth, indicating susceptibility of the as-fabricated components to premature creep failure. Such heterogeneity in microstructural and mechanical behavior was attributed to recurring solid-state phase transformations. Subsequently, an interlayer temperature control strategy was implemented, wherein maintaining interlayer temperature above the martensitic start temperature mitigated the heterogeneous microstructural and plastic response in the as-fabricated condition. Findings open pathways to achieving deformation-localization- and creep-resistant microstructures in WA-DED fabricated particle-strengthened CSEF steel components, reducing reliance on post-welding heat treatments—conventionally required to enhance creep resistance—and enabling on-demand, short lead-time fabrication of next-generation power-plant components.

Heat affected zones↗

NASA NTRS1992

Influence of grain size on the creep behavior of HfC-dispersed NiAl

Rapid solidification technology has been utilized to produce a NiAl-4(wt pct)HfC composite containing about 0.3 vol pct HfC as dispersed 50 nm particles. Study of the 1300 K compressive creep properties demonstrated that the initial, small grain size microstructure was unstable under slow strain rate deformation conditions. The grain growth which occurred during testing led to considerable strengthening. Subsequent measurements of the creep properties of the coarse grained specimens revealed that this strength was achieved by a large increase in the activation energy for deformation without any change in the stress exponent. Based on this work, it is concluded that large grain microstructures will be required for optimum elevated temperature creep properties in dispersed NiAl.

Whittenberger, J. D.↗

DOE OSTI2023

Applying molecular dynamics simulations to the study of micro cold spray of yttria

Micro cold spray (MCS) is a novel manufacturing process with proven success depositing dense, thick films of technical ceramics without the need for elevated processing temperatures or chemical precursors. The process transforms a loose sub-micrometer powder into an adherent film with mechanical properties approaching that of the bulk material through a phenomenon known as room temperature impact consolidation. While this phenomenon has been demonstrated for a wide variety of ceramic materials and film substrates, yttria stands out as a material that is both well-characterized in experiments and of significant interest for industrial applications due to its excellent refractory properties. This dissertation seeks to investigate the fundamental mechanisms that enable room temperature impact consolidation by using molecular dynamics (MD) simulations of yttria particle impacts and characterizing the deformation behavior of the system.

36 MATERIALS SCIENCE↗