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NASA NTRS1991

Holographic study of conventional and negative Poisson's ratio metallic foams - Elasticity, yield and micro-deformation

An experimental study by holographic interferometry is reported of the following material properties of conventional and negative Poisson's ratio copper foams: Young's moduli, Poisson's ratios, yield strengths and characteristic lengths associated with inhomogeneous deformation. The Young's modulus and yield strength of the conventional copper foam were comparable to those predicted by microstructural modeling on the basis of cellular rib bending. The reentrant copper foam exhibited a negative Poisson's ratio, as indicated by the elliptical contour fringes on the specimen surface in the bending tests. Inhomogeneous, non-affine deformation was observed holographically in both foam materials.

Chen, C. P.↗

NASA NTRS1993

Thermal stress effects in intermetallic matrix composites

Intermetallic matrix composites develop residual stresses from the large thermal expansion mismatch (delta-alpha) between the fibers and matrix. This work was undertaken to: establish improved techniques to measure these thermal stresses in IMC's; determine residual stresses in a variety of IMC systems by experiments and modeling; and, determine the effect of residual stresses on selected mechanical properties of an IMC. X ray diffraction (XRD), neutron diffraction (ND), synchrotron XRD (SXRD), and ultrasonics (US) techniques for measuring thermal stresses in IMC were examined and ND was selected as the most promising technique. ND was demonstrated on a variety of IMC systems encompassing Ti- and Ni-base matrices, SiC, W, and Al2O3 fibers, and different fiber fractions (Vf). Experimental results on these systems agreed with predictions of a concentric cylinder model. In SiC/Ti-base systems, little yielding was found and stresses were controlled primarily by delta-alpha and Vf. In Ni-base matrix systems, yield strength of the matrix and Vf controlled stress levels. The longitudinal residual stresses in SCS-6/Ti-24Al-llNb composite were modified by thermomechanical processing. Increasing residual stress decreased ultimate tensile strength in agreement with model predictions. Fiber pushout strength showed an unexpected inverse correlation with residual stress. In-plane shear yield strength showed no dependence on residual stress. Higher levels of residual tension led to higher fatigue crack growth rates, as suggested by matrix mean stress effects.

Wright, P. K.↗

DOE OSTI2025

Sustainable Shape Memory Elastomers with Reduced Melt Viscosity and Enhanced Stiffness

Melt reactive processing of lignin with nitrile rubber is a promising approach to synthesizing shape memory materials. The strong intramolecular interactions in lignin macromolecular structures, caused by π–π stacking in aromatic rings and hydrogen bonding, often result in large phase separation or low miscibility with rubbers. In this study, we investigated the chemical and molecular characteristics, as well as the stiffness and complex viscosity, of modified kraft lignin melt-reacted with an acrylonitrile/butadiene copolymer containing 41% acrylonitrile (NBR41). To enhance the macromolecular compatibility of kraft lignin with NBR41, kraft lignin was cross-linked with poly(propylene glycol) diglycidyl ether (PPDE) and trimethylolpropane triglycidyl ether (TTE), both rich in epoxy reactive groups capable of forming chemical bonds with hydroxyl and carboxyl groups. Here, our findings demonstrate that the modification of kraft lignin with PPDE and TTE resulted in significantly increased stiffness of the composites. The elastic modulus of NBR41-Kraft lignin-PPDE and NBR41-Kraft lignin-TTE increased by 82 and 162%, respectively. Both the yield strength and Young’s modulus of these two samples showed dramatic improvements. Specifically, the yield strength and Young’s modulus of NBR41-Kraft lignin-TTE increased nearly 4 and 3-fold, respectively, compared to the control sample. Interestingly, despite significant improvements in mechanical properties, the viscosity of NBR41-Kraft lignin-PPDE was substantially lower than that of the control sample. At 210 °C and an angular frequency of 1 rad/s, the complex viscosity of NBR41-Kraft lignin was approximately 100.25 ± 4.77 kPa·s, while that of NBR41-Kraft lignin-PPDE was significantly lower at 56 ± 0.93 kPa·s. These findings were validated through Fourier transform infrared spectroscopy, scanning electron microscopy, dynamic mechanical analysis, thermal characterization, rheological tests, and quasi-elastic neutron scattering techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Location-Specific Microstructures and Properties of Haynes 282 Alloy with Laser-Wire DED Processing

In this work, the location-specific microstructures in terms of grain morphology, texture, γ′ precipitates, carbides, and residual strains were investigated in a series of laser-wire direct energy deposition (LW-DED) Haynes 282 alloys with varied processing parameters. A bimodal grain distribution was found in these as-printed and heat-treated alloys with columnar grains within the layers and fine equiaxed grains at the interlayer regions. Dominant <001> texture along the build direction with more obvious <111> orientation preference exists at the bottom layers, compared to the top layers. The gradient γ′-precipitates size distribution contributes predominantly to the observed gradient hardness distribution in the as-printed samples. The heat-treated 282 exhibit comparable yield strengths to those conventionally-processed counterparts, while the observed small deviation in their yield strengths is attributed to the Hall-Petch effect. This work establishes the correlation between location-specific microstructures and mechanical properties, providing valuable insights into future printing parameters and heat-treatment optimization.

Haynes 282↗

NASA NTRS1972

The role of grain size and shape in the strengthening of dispersion hardened nickel alloys

Thermomechanical processing was used to develop various microsstructures in Ni, Ni-2ThO2, Ni-20Cr, Ni-20CR-2ThO2, Ni-20Cr-10W-and Ni-20Cr-10W-2ThO2. The yield strength at 25 C increased with substructure refinement according to the Hall-Petch relation, and substructure refinement was a much more potent means of strengthening than was dispersion hardening. At elevated temperature (1093 C), the most important microstructural feature affecting strength was the grain aspect ratio (grain length, L, divided by grain width, 1. The yield strength and creep strength increased linearly with increasing L/1.

Wilcox, B. A.↗

NASA NTRS1980

Evaluation of the stress corrosion cracking resistance of several high strength low alloy steels

The stress corrosion cracking resistance was studied for high strength alloy steels 4130, 4340, for H-11 at selected strength levels, and for D6AC and HY140 at a single strength. Round tensile and C-ring type specimens were stressed up to 100 percent of their yield strengths and exposed to alternate immersion in salt water, salt spray, the atmosphere at Marshall Space Flight Center, and the seacoast at Kennedy Space Center. Under the test conditions, 4130 and 4340 steels heat treated to a tensile strength of 1240 MPa (180 ksi), H-11 and D6AC heat treated to a tensile strength of 1450 MPa (210 ksi), and HY140 (1020 MPa, 148 ksi) are resistant to stress corrosion cracking because failures were not encountered at stress levels up to 75 percent of their yield strengths. A maximum exposure period of one month for alternate immersion in salt water or salt spray and three months for seacoast is indicated for alloy steel to avoid false indications of stress corrosion cracking because of failure resulting from severe pitting.

Humphries, T. S.↗

NASA NTRS1974

Effects of porosity on weld-joint tensile strength of aluminum alloys

Tensile properties in defect-free weldments of aluminum alloys 2014-T6 and 2219-T87 (sheet and plate) are shown to be related to the level or concentration of induced simulated porosity. The scatter diagram shows that the ultimate tensile strength of the weldments displays the most pronounced linear relationship with the level of porosity. The relationships between yield strength or elongation and porosity are either trivial or inconsequential in the lower and intermediate levels of porosity content. In highly concentrated levels of porosity, both yield strength and elongation values decrease markedly. Correlation coefficients were obtained by simple straight line regression analysis between the variables of ultimate tensile strength and pore level. The coefficients were greater, indicating a better correlation, using a pore area accumulation concept or pore volume accumulation than the accumulation of the pore diameters. These relationships provide a useful tool for assessing the existing aerospace radiographic acceptance standards with respect to permissible porosity. In addition, these relationships, in combination with known design load requirements, will serve as an engineering guideline in determining when a weld repair is necessary based on accumulative pore level as detected by radiographic techniques.

Lovoy, C. V.↗

NASA NTRS1943

The Effect of Artificial Aging on the Tensile Properties of Alclad 24S-T and 24S-T Aluminum Alloy

An experimental study was made to determine the effect of artificial aging on the tensile properties of alclad 24S-T and 24S-T aluminum-alloy sheet material. The results of the tests show that certain combinations of aging time and temperature cause a marked increase in the yield strength and a small increase in the ultimate strength; these increases are accompanied by a very large decrease in elongation. A curve is presented that shows the maximum yield strengths that can be obtained by aging this material at various combinations of time and temperature. The higher values of yield stress are obtained in material aged at relatively longer times and lower temperatures.

ALUMINUM ALLOYS-TEMPERATURES, HIGH↗

NASA NTRS1977

The effect of microstructure and strength on the fracture toughness of an 18 Ni, 300 grade maraging steel

Fractography and metallographic sectioning were used to investigate the influence of microstructure and strength on the fracture toughness (KIc) and fracture mechanism of an 18 Ni, 300 grade maraging steel. Increased yield strength from 1442 to 2070 MN/m squared through precipitation hardening results in a KIc loss from 143 to 55 MN/m superscript 3/2. Ti (C,N) Ti2S, and TiC inclusions in sizes from 1 to 8, 1 to 15, and 0.1 to 2 microns respectively serve as sites for void nucleation and lead to fracture by the dimpled rupture process in all strength levels considered. TiC nucleated dimples occupy more than half the fracture in all conditions. Void nucleation rate and resultant number of dimples per unit area of fracture increase with increasing yield strength. Average dimple size decreases with increasing strength and/or overaging which follows from the decreasing amount of stable void growth measured by sectioning tensile specimens. Void growth is assisted by crack branching along a path of TiC inclusions. Coalescence occurs in the highest strength materials by a combination of TiC void nucleation and premature separation at strengthening precipitates.

Psioda, J. A.↗

NASA NTRS1972

Fatigue crack tip deformation and fatigue crack propagation

The effects of stress ratio, prestress cycling and plate thickness on the fatigue crack propagation rate are studied on 2024-T351 aluminum alloy. Fatigue crack propagation rate increases with the plate thickness and the stress ratio. Prestress cycling below the static yield strength has no noticeable effect on the fatigue crack propagation rate. However, prestress cycling above the static yield strength causes the material to strain harden and increases the fatigue crack propagation rate. Crack tip deformation is used to study the fatigue crack propagation. The crack tip strains and the crack opening displacements were measured from moire fringe patterns. The moire fringe patterns were obtained by a double exposure technique, using a very high density master grille (13,400 lines per inch).

Kang, T. S.↗

DOE OSTI2024

Understanding the effect of refractory metal chemistry on the stacking fault energy and mechanical property of Cantor-based multi-principal element alloys

Multi-principal-element alloys (MPEAs) based on 3d-transition metals show remarkable mechanical properties. In this study, the stacking fault energy (SFE) in face-centered cubic (fcc) alloys is a critical property that controls underlying deformation mechanisms and mechanical response. Here, we present an exhaustive density-functional theory study on refractory- and copper-reinforced Cantor-based systems to ascertain the effects of refractory metal chemistry on SFE. We find that even a small percent change in refractory metal composition significantly changes SFEs, which correlates favorably with features like electronegativity variance, size effect, and heat of fusion. For fcc MPEAs, we also detail the changes in mechanical properties, such as bulk, Young's, and shear moduli, as well as yield strength. A Labusch-type solute-solution-strengthening model was used to evaluate the temperature-dependent yield strength, which, combined with SFE, provides a design guide for high-performance alloys. We also analyzed the electronic structures of two down-selected alloys to reveal the underlying origin of optimal SFE and strength range in refractory-reinforced fcc MPEAs. These new insights on tuning SFEs and modifying composition-structure-property correlation in refractory- and copper-reinforced MPEAs by chemical disorder, provide a chemical route to tune twinning- and transformation-induced plasticity behavior in fcc MPEAs.

36 MATERIALS SCIENCE↗

NASA NTRS2006

Heat Treatment of Friction-Stir-Welded 7050 Aluminum Plates

A method of heat treatment has been developed to reverse some of the deleterious effects of friction stir welding of plates of aluminum alloy 7050. This alloy is considered unweldable by arc and high-energy-density beam fusion welding processes. The alloy can be friction stir welded, but as-welded workpieces exhibit low ductility, low tensile and yield strengths, and low resistance to stress corrosion cracking. Heat treatment according to the present method increases tensile and yield strengths, and minimizes or eliminates stress corrosion cracking. It also increases ductility. This method of heat treatment is a superior alternative to a specification-required heat treatment that caused the formation of large columnar grains, which are undesired. Workpieces subjected to the prior heat treatment exhibited elongations <2 percent, and standard three-point bend specimens shattered. The development of the present heat treatment method was guided partly by the principles that (1) by minimizing grain sizes and relieving deformation stresses, one can minimize or eliminate stress corrosion cracking and (2) the key to maximizing strength and eliminating residual stresses is to perform post-weld solution heating for as long a time as possible while incurring little or no development of large columnar grains in friction stir weld nuggets. It is necessary to perform some of the solution heat treatment (to soften the alloy and improve machine welding parameters) before welding. The following is an example of thickness- dependent pre- and post-weld heat treatments according to the present method: For plates 0.270 in. (approx.6.86 mm) thick milled from plates 4.5 in. (114.3 mm) thick, perform pre-weld solution heating at 890 F (477 C) for 1 hour, then cool in air. After friction stir welding, perform solution heating for 10 minutes, quench, hold at room temperature for 96 hours, then age at 250 F (121 C) for 5 hours followed by 325 F (163 C) for 27 hours.

Petter, George E.↗

NASA NTRS1973

Propellant isolation shutoff valve program

An analysis and design effort directed to advancing the state-of-the-art of space storable isolation valves for control of flow of the propellants liquid fluorine/hydrazine and Flox/monomethylhydrazine is discussed. Emphasis is on achieving zero liquid leakage and capability of withstanding missions up to 10 years in interplanetary space. Included is a study of all-metal poppet sealing theory, an evaluation of candidate seal configurations, a valve actuator trade-off study and design description of a pneumo-thermally actuated soft metal poppet seal valve. The concepts and analysis leading to the soft seal approach are documented. A theoretical evaluation of seal leakage versus seal loading, related finishes and yield strengths of various materials is provided. Application of a confined soft aluminum seal loaded to 2 to 3 times yield strength is recommended. Use of either an electro-mechanical or pneumatic actuator appears to be feasible for the application.

Merritt, F. L.↗

NASA NTRS2010

Repeatability and Reproducibility of Compression Strength Measurements Conducted According to ASTM E9

Ten commercial laboratories participated in an interlaboratory study to establish the repeatability and reproducibility of compression strength tests conducted according to ASTM International Standard Test Method E9. The test employed a cylindrical aluminum AA2024-T351 test specimen. Participants measured elastic modulus and 0.2 % offset yield strength, YS(0.2 % offset), using an extensometer attached to the specimen. The repeatability and reproducibility of the yield strength measurement, expressed as coefficient of variations were cv(sub r)= 0.011 and cv(sub R)= 0.020 The reproducibility of the test across the laboratories was among the best that has been reported for uniaxial tests. The reported data indicated that using diametrically opposed extensometers, instead of a single extensometer doubled the precision of the test method. Laboratories that did not lubricate the ends of the specimen measured yield stresses and elastic moduli that were smaller than those measured in laboratories that lubricated the specimen ends. A finite element analysis of the test specimen deformation for frictionless and perfect friction could not explain the discrepancy, however. The modulus measured from stress-strain data were reanalyzed using a technique that finds the optimal fit range, and applies several quality checks to the data. The error in modulus measurements from stress-strain curves generally increased as the fit range decreased to less than 40 % of the stress range.

Luecke, William E.↗

NASA NTRS1991

On improving the fracture toughness of a NiAl-based alloy by mechanical alloying

Mechanical alloying (MA) has been used to process the NiAl-based alloy Ni-35Al-20Fe, such that a fine-grain (about 2 microns) microstructure is obtained through the addition of 2 vol pct Y2O3 particles. When compared to a conventionally processed, coarse-grained (about 28 microns) Ni-35-20 alloy without the Y2O3 particles, the MA alloy exhibits two to three times higher fracture toughness values, despite a 50-percent increase in yield strength. Room-temperature K(O) values as high as 34 MPa sq rt m are observed, accompanied by a yield strength in excess of 1100 MPa. Fractography confirms a change in fracture characteristics of the fine-grained MA alloy.

Kostrubanic, J.↗

NASA NTRS1985

Characteristics of Basaltic Lava Flows on Venus

Some ideas relating to the formation of lava flows on Venus are reviewed. The surface morphological features seen in the panoramic images made by the Venera 13 and 14 landers are examined in detail. The major element compositions measured by the Soviet probes indicate that the surface rocks at the Venera 13 site resemble a terrestrial tholeite composite whereas the Venera 14 rocks are similar to terrestrial alkali basalts. Few data exist on the rheological properties of such magma types on Earth; these properties are a strong function of magma volatile content, and there are important gaps in our knowledge of the typical volatiles to be associated with the magmas on Venus. However, the suggestion that Venusian magmas may be water poor together with consideration of the fact that the high Venusian surface temperatures may cause magmas to experience up to 50 K less cooling during their rise to the surface than corresponding terrestrial counterparts, leads to the finding that Venusian magmas may typically have plastic viscosities, E, up to a factor of three greater than terrestrial counterparts on eruption. A similar analysis of yield strength variations with temperature, magma composition and volatile content suggests that temperature will exert the main control and that Venusian magma yield strengths, Y, may be a factor of several times smaller than those of terrestrial equivalents.

Wilson, L.↗

NASA NTRS1983

Development of tough, strong, iron-base alloy for cryogenic applications

The development of an iron-base alloy that combines the normally divergent properties of high toughness and high strength at cryogenic temperatures is discussed. Specifically, alloy properties were sought which at -196 C would exhibit a fracture toughness of 220 MPa-m(1/2) with a corresponding yield strength of 1.4 GPa (200 ksi). Early work showed that high toughness could be achieved in Fe-12Ni alloys containing reactive metal additions such as Al, Nb, Ti, and V. Further research emphasized strengthening of these tough alloys by thermomechanical processing and the addition of Cu. Results showed that high strength and high toughness could be achieved in a single alloy at temperatures as low as -196 C. An alloy with composition Fe-12Ni-9.5Al-2Cu exhibited a yield strength of 1.65 GPa with a corresponding fracture toughness of 220 MPa-m(1/2) at -196 C. Strengthening due to Cu additions to the Fe-12Ni base alloys results primarily from precipitation of Cu-rich epsilon particles approximately 20 nm in diameter. Strengthening mechanisms are discussed in terms of an elastic modulus hardening model and are supported by transimission electron microscopy examinations of selected test specimens.

Stephens, J. R.↗

DOE OSTI2026

Microstructural evolution, defect mitigation, and precipitation behavior in AA6061 via laser powder bed fusion with high-temperature substrate heating

Defects, particularly solidification cracking, remain persistent challenges in the laser powder bed fusion (LPBF) processing of AA6061 aluminum alloy. This study systematically investigates defect mitigation, microstructural evolution, and mechanical properties associated with high-temperature substrate preheating at 500 °C. Comprehensive microstructural analyses, including characterization of defects, grain structures, and precipitation behavior, were performed on samples in both as-built and T6 heat-treated states. Elevated preheating substantially reduced solidification cracking across a wide processing window, while demonstrating decreased crack sensitivity to laser parameters. Columnar cracks along the build direction were observed despite substrate preheating. Lack-of-fusion and keyhole porosity were effectively eliminated, though gas-induced microporosity persisted at higher powers. In-depth characterization of two distinct laser power and speed conditions confirmed the formation of micron-sized, non-coherent Mg 2 Si precipitates under heated substrate conditions, alongside α-AlFeCrMnSi intermetallic phases indicative of in-situ thermal effects during fabrication. Subsequent T6 heat treatment revealed the formation of fine, coherent needle-shaped β″ strengthening precipitates. Despite substantial differences in processing parameters, comparable mechanical properties were measured in the as-built samples (∼52 MPa yield strength, ∼130 MPa tensile strength), primarily due to reduced strain hardening effects and consistent precipitation characteristics. Meanwhile, the T6 heat treatment led to significant improvement in properties, enhancing yield strength by over 400%, aligning closely with the performance of conventional wrought AA6061-T6. These findings underscore that high-temperature substrate preheating offers an effective means to suppress cracks, control precipitation, and enhance mechanical performance in LPBF-processed AA6061.

36 MATERIALS SCIENCE↗