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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 NTRS1985

Mechanical properties of Inconel 718 and Nickel 201 alloys after thermal histories simulating brazing and high temperature service

An experimental investigation was made to evaluate two nickel base alloys (Nickel-201 and Inconel-718) in three heat treated conditions. These conditions were: (1) annealed; (2) after thermal exposure simulating a braze cycle; and (3) after a thermal exposure simulating a braze cycle plus one operational lifetime of high temperature service. For the Nickel-201, two different braze cycle temperatures were evaluated. A braze cycle utilizing a lower braze temperature resulted in less grain growth for Nickel-201 than the standard braze cycle used for joining Nickel-201 to Inconel-718. It was determined, however, that Nickel-201, was marginal for temperatures investigated due to large grain growth. After the thermal exposures described above, the mechanical properties of Nickel-201 were degraded, whereas similar exposure on Inconel-718 actually strengthened the material compared with the annealed condition. The investigation included tensile tests at both room temperature and elevated temperatures, stress-rupture tests, and metallographic examination.

James, W. F.↗
NASA NTRS1978

Arc termination cracks in Inconel 718 and Incoloy 903

The welding of the nickel base, heat resistant alloys that are used extensively for welded Shuttle engine components revealed solidification cracking characteristics at weld termination points. If not detected and removed, these crater cracks may cause costly component failure. To better understand this characteristic, welding termination techniques were studied and methods developed to eliminate crater cracks. It was determined that weld termination solidification cracking can be eliminated by controlled decrease of welding current, welding voltage, wire feed, and travel speed.

Bayless, E.↗
NASA NTRS1983

Microstructural evolution in the HAZ of Inconel 718 and correlation with the hot ductility test

The nickel-base alloy 718 was evaluated to study the role of preweld heat treatment in reducing or eliminating heat-affected zone hot cracking. Three heat treatments were studied using the Gleeble hot ductility test. A modified hot ductility test was also used to follow the evolution of microstructure during simulated welding thermal cycles. The microstructural evolution was correlated with the hot ductility data in order to evaluate the mechanism of hot cracking in alloy 718. The correlation of hot ductility with microstructure showed that recrystallization, grain growth, and dissolution of precipitates did not in themselves cause any loss of ductility during cooling. Ductility loss during cooling was not initiated until the constitutional liquation of NbC particles was observed in the microstructure. Laves-type phases were found precipitated in the solidified grain boundaries but were not found to correlate with any ductility loss parameter. Mechanisms are reviewed which help to explain how heat treatment controls the hot crack susceptibility of alloy 718 as measured in the hot ductility test.

Thompson, R. G.↗
NASA NTRS1990

Preliminary study on pressure brazing and diffusion welding of Nb-1Zr to Inconel 718

Future space power systems may include Nb-1Zr/Inconel 718 dissimilar metal joints for operation at 1000 K for 60,000 h. The serviceability of pressure-brazed and diffusion-welded joints was investigated. Ni-based metallic glass foil filler metals were used for brazing. Ni and Fe foils were used as diffusion welding inter-layers. Joint soundness was determined by metallographic examination in the as-brazed and as-welded condition, after aging at 1000 K, and after thermal cycling. Brazed joints thermally cycled in the as-brazed condition and diffusion-welded joints were unsatisfactory because of cracking problems. Brazed joints may meet the service requirements if the joints are aged at 1000 K prior to thermal cycling.

Moore, T. J.↗
NASA NTRS1990

Inhomogeneous deformation in INCONEL 718 during monotonic and cyclic loadings

The paper concentrates on the relation between microstructural observations of the dislocation structures and the macroscopic deformation responses of both aged and homogenized precipitate-hardened alloys at room temperature. The deformation responses are compared to the cyclic deformation response of an aged precipitate-hardened alloy. Early in the deformation, one deformation band per grain and little evidence of work hardening are observed; with increased deformation, work hardening begins, more bands nucleate, and their spacing becomes similar to that in the aged material. It is pointed out that the degree of coarseness of inhomogeneous deformation is not a result of a softening process within the bands due to precipitate shearing, but it is a function of the amount of work hardening within the bands.

Worthem, D. W.↗
NASA NTRS1991

Model of the Frictional Heating of Inconel 718 and Titanium (ti-6al-4v) in Helium

A computer model of the frictional heating of metals in an inert environment has been developed. The model incorporates the effects of the heat loss from the samples due to conduction, radiation, and convection to the surroundings. This model allows the measured temperatures to be used to determine the amount of heat produced at the interface during the experiment by the sliding contact of two different metallic samples. The results of the simulation for an experiment run at the NASA White Sands Test Facility (WSTF) show that for the same heat production at the interface the heat losses have a significant effect on the temperatures in the samples. But, the heat losses do not significantly affect the different calculated heat flows (or friction coefficients), at the interface, that are necessary to correlate the measured temperatures.

Skowlund, Christopher T.↗
NASA NTRS1995

Probabilistic Material Strength Degradation Model for Inconel 718 Components Subjected to High Temperature, High-Cycle and Low-Cycle Mechanical Fatigue, Creep and Thermal Fatigue Effects

The development of methodology for a probabilistic material strength degradation is described. The probabilistic model, in the form of a postulated randomized multifactor equation, provides for quantification of uncertainty in the lifetime material strength of aerospace propulsion system components subjected to a number of diverse random effects. This model is embodied in the computer program entitled PROMISS, which can include up to eighteen different effects. Presently, the model includes five effects that typically reduce lifetime strength: high temperature, high-cycle mechanical fatigue, low-cycle mechanical fatigue, creep and thermal fatigue. Results, in the form of cumulative distribution functions, illustrated the sensitivity of lifetime strength to any current value of an effect. In addition, verification studies comparing predictions of high-cycle mechanical fatigue and high temperature effects with experiments are presented. Results from this limited verification study strongly supported that material degradation can be represented by randomized multifactor interaction models.

Bast, Callie C.↗
NASA NTRS1998

Determination of Yield and Flow Surfaces for Inconel 718 Under Axial-Torsional Loading at Temperatures Up to 649 C

An experimental program to determine flow surfaces has been established and implemented for solution annealed and aged IN718. The procedure involved subjecting tubular specimens to various ratios of axial-torsional stress at temperatures between 23 and 649 C and measuring strain with a biaxial extensometer. Each stress probe corresponds to a different direction in stress space, and unloading occurs when a 30 microstrain (1 micro eplison = 10(exp -6) mm/mm) offset is detected. This technique was used to map out yield loci in axial-torsional stress space. Flow surfaces were determined by post-processing the experimental data to determine the inelastic strain rate components. Surfaces of constant inelastic strain rate (SCISRS) and surfaces of constant inelastic power (SCIPS) were mapped out in the axial-shear stress plane. The von Mises yield criterion appeared to closely fit the initial loci for solutioned IN718 at 23 C. However, the initial loci for solutioned IN718 at 371 and 454 C, and all of the initial loci for aged IN718 were offset in the compression direction. Subsequent loci showed translation, distortion, and for the case of solutioned IN718, a slight cross effect. Aged IN718 showed significantly more hardening behavior than solutioned IN718.

Gil, Christopher M.↗
NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, T.↗
NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human‐rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30‐sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post‐processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one‐way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, Tracie↗
NASA NTRS2016

Study of Material Consolidation at Higher Throughput Parameters in Selective Laser Melting of Inconel 718

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Prater, Tracie↗