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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

The Relation Between Alloy Chemistry and Hot-Cracking

Hot cracking is a problem in welding 2195 aluminum-lithium alloy. Weld wire additives seem to reduce the problem. This study proposes a model intended to clarify the way alloying elements affect hot-cracking. The brittle temperature range of an alloy extends wherever the tensile stress required to move the meniscus of the liquid film at the grain/dendrite boundaries is less than the bulks flow stress Sigma(sub B) of the grains: 2gamma/delta <= sigma(sub B) + P where gamma is boundary film surface tension delta= boundary film thickness P = gas pressure (Some alloys outgas.) If the above condition is not met, the grains deform under stress and the liquid film remains in place. Curves of 2gamma/delta and sigma(sub B) vs. temperature in the range just below the melting temperature determine the hot cracking susceptibility of an alloy. Both are zero at onset of solidification. sigma(sub B) rises as the thermal activation of the slip mechanism is reduced. 2gamma/delta rises as the film thickness delta which can be estimated from the Scheil equation, drops. But, given an embrittled alloy, whether the alloy actually cracks is determined by the strain imposed upon it in the embrittled condition. A critical strain is estimated, Epsilon(sub C) on the order of Epsilon(sub C) is approximately delta/l where L = grain size and where the the volume increment due to the strain, concentrated at the liquid film, is on the order of the liquid film volume. In the early 80's an empirical critical strain cracking envelope Epsilon(sub C)(T) was incorporated into a damage criterion to estimate the effect of welding parameters on the formation of microfissures in a superalloy with good results. These concepts, liquid film decoherence vs. grain bulk deformation and critical strain, form the key elements of a quantitative theory of hot-cracking applicable for assessing the effect of alloying elements on hot-cracking during welding.

Nunes, A. C., Jr.↗
NASA NTRS2013

Fatigue Resistance of Liquid-assisted Self-repairing Aluminum Alloys Reinforced with Shape Memory Alloys

A self-repairing aluminum-based composite system has been developed using a liquid-assisted healing theory in conjunction with the shape memory effect of wire reinforcements. The metal-metal composite was thermodynamically designed to have a matrix with a relatively even dispersion of a low-melting eutectic phase, allowing for repair of cracks at a predetermined temperature. Additionally, shape memory alloy (SMA) wire reinforcements were used within the composite to provide crack closure. Investigators focused the research on fatigue cracks propagating through the matrix in order to show a proof-of-concept Shape Memory Alloy Self-Healing (SMASH) technology for aeronautical applications.

Wright, M. Clara↗
NASA NTRS2008

Effects of Solute Concentrations on Kinetic Pathways in Ni-Al-Cr Alloys

The kinetic pathways resulting from the formation of coherent gamma'-precipitates from the gamma-matrix are studied for two Ni-Al-Cr alloys with similar gamma'-precipitate volume fractions at 873 K. The details of the phase decompositions of Ni-7.5Al-8.5Cr at.% and Ni-5.2Al-14.2Cr at.% for aging times from 1/6 to 1024 h are investigated by atom-probe tomography, and are found to differ significantly from a mean-field description of coarsening. The morphologies of the gamma'-precipitates of the alloys are similar, though the degrees of gamma'-precipitate coagulation and coalescence differ. Quantification within the framework of classical nucleation theory reveals that differences in the chemical driving forces for phase decomposition result in differences in the nucleation behavior of the two alloys. The temporal evolution of the gamma'-precipitate average radii and the gamma-matrix supersaturations follow the predictions of classical coarsening models. The compositional trajectories of the gamma-matrix phases of the alloys are found to follow approximately the equilibrium tie-lines, while the trajectories of the gamma'-precipitates do not, resulting in significant differences in the partitioning ratios of the solute elements.

Booth-Morrison, Christopher↗
NASA NTRS1985

The effect of material heterogeneity and random loading on the mechanics of fatigue crack growth

This paper reviews experimental work on the influence of variable amplitude or random loads on the mechanics and micromechanisms of fatigue crack growth. Implications are discussed in terms of the crack driving force, local plasticity, crack closure, crack blunting, and microstructure. Due to heterogeneity in the material's microstructure, the crack growth rate varies with crack tip position. Using the weakest link theory, an expression for crack growth rate is obtained as the expectation of a random variable. This expression is used to predict the crack growth rates for aluminum alloys, a titanium alloy, and a nickel steel in the mid-range region. It is observed, using the present theory, that the crack growth rate obeys the power law for small stress intensity factor range, and that the power is a function of a material constant.

Srivatsan, T. S.↗
NASA NTRS1974

Skylab Experiment M552: Exothermic Brazing

The M552 Skylab experiment reveals that brazing in space is feasible. It successfully demonstrated the ability to retain molten metal within a braze tube joint system. Surface energy was the dominant operative force system controlling liquid metal for this experiment. The zero gravity environment for brazing resulted in several differences; increased solubility, increased liquid spreading, more uniform menisci (liquid/vapor interface) and a reduction of braze alloy shrinkage defects. The residual radioactive intensity and location of the redistributed isotope was interpreted to provide a sequential history of braze alloy movement during the melt-flow-solidification stages of the process. Convection theory applied to M552 was validated but some results were not explainable by it, i.e., increased nickel transport and the radial mixing of the silver isotope on samples SLN-2 and SLN-4. All characteristics of thermal analysis appeared to react as expected but heat conduction rates increased because of increased extent, rate and uniformity of braze alloy spreading.

J R Williams↗
NASA NTRS1993

Thermophysical properties of simple liquid metals: A brief review of theory

In this paper, we review the current theory of the thermophysical properties of simple liquid metals. The emphasis is on thermodynamic properties, but we also briefly discuss the nonequilibrium properties of liquid metals. We begin by defining a 'simple liquid metal' as one in which the valence electrons interact only weakly with the ionic cores, so that the interaction can be treated by perturbation theory. We then write down the equilibrium Hamiltonian of a liquid metal as a sum of five terms: the bare ion-ion interaction, the electron-electron interaction, the bare electron-ion interaction, and the kinetic energies of electrons and ions. Since the electron-ion interaction can be treated by perturbation, the electronic part contributes in two ways to the Helmholtz free energy: it gives a density-dependent term which is independent of the arrangement of ions, and it acts to screen the ion-ion interaction, giving rise to effective ion-ion pair potentials which are density-dependent, in general. After sketching the form of a typical pair potential, we briefly enumerate some methods for calculating the ionic distribution function and hence the Helmholtz free energy of the liquid: monte Carlo simulations, molecular dynamics simulations, and thermodynamic perturbation theory. The final result is a general expression for the Helmholtz free energy of the liquid metal. It can be used to calculate a wide range of thermodynamic properties of simple metal liquids, which we enumerate. They include not only a range of thermodynamic coefficients of both metals and alloys, but also many aspects of the phase diagram, including freezing curves of pure elements and phase diagrams of liquid alloys (including liquidus and solidus curves). We briefly mention some key discoveries resulting from previous applications of this method, and point out that the same methods work for other materials not normally considered to be liquid metals (such as colloidal suspensions, in which the suspended microspheres behave like ions screened by the salt solution in which they are suspended). We conclude with a brief discussion of some non-equilibrium (i.e., transport) properties which can be treated by an extension of these methods. These include electrical resistivity, thermal conductivity, viscosity, atomic self-diffusion coefficients, concentration diffusion coefficients in alloys, surface tension and thermal emissivity. Finally, we briefly mention two methods by which the theory might be extended to non-simple liquid metals: these are empirical techniques (i.e., empirical two- and three-body potentials), and numerical many-body approaches. Both may be potentially applicable to extremely complex systems, such as nonstoichiometric liquid semiconductor alloys.

Stroud, David↗
NASA NTRS1998

Orbital Processing of Eutectic Rod-Like Arrays

The eutectic is one of only three solidification classes that exist. The others are isostructural and peritectic-class reactions, respectively. Simplistically, in a binaryeutectic phase diagram, a single liquid phase isothermally decomposes to two solid phases in a cooperative manner. The melting point minimum at the eutectic composition, isothermal solidification temperature, near-isocompositional solidification and refined solidification microstructure lend themselves naturally to such applications as brazing and soldering; industries that eutectic alloys dominate. Interest in direct process control of microstructures has led, more recently, to in-situ eutectic directional solidification with applications in electro-magnetics and electro-optics. In these cases, controlled structural refinement and the high aspect ratio and regularity of the distributed eutectic phases is highly significant to the fabrication and application of these in-situ natural composites. The natural pattern formation and scaling of the dispersed phase on a sub-micron scale has enormous potential application, since fabricating bulk materials on this scale mechanically has proven to be particularly difficult. It is thus of obvious importance to understand the solidification of eutectic materials since they are of great commercial significance. The dominant theory that describes eutectic solidification was derived for diffusion-controlled growth of alloys where both solid eutectic phases solidify metallically, i.e. without faceting at the solidification interface. Both high volume fraction (lamellar) and low volume fraction (rod-like) regular metallic arrays are treated by this theory. Many of the useful solders and brazements, however, and most of the regular in-situ composites are characterized by solidification reactions that are faceted/non-faceted in nature, rather than doubly non-faceted (metallic). Further, diffusion-controlled growth conditions are atypical terrestrially since gravitationally-driven convection is pervasive. As a consequence, it is important to determine whether these faceted/non-faceted composites behave in the same manner as their doubly non-faceted counterparts, particularly in the presence of convection. Prior analytical convective sensitivity testing of this theory predicted insensitivity. Prior experimental testing of this theory offered broad-based agreement between theory and experiment, though most results were for high volume fraction lamellar eutectics that solidified without faceting at the solidification interface. Directional solidification experiments of low volume fraction rod eutectics under damped (microgravity or magnetic field) conditions, however, have demonstrated significant sensitivity, challenging this fundamental theory. More recent theories have been proposed which introduce kinetic undercooling, faceting, fluid shear of the solute redistribution zone and the possibility that the interface composition is not the same as the bulk liquid composition. This program tests the established and proposed analytical theories and addresses the origins of discrepancies between the experimental and analytical results.

Larson, David J., Jr.↗
NASA NTRS1977

On the origin of stable remanence in pseudo-single domain grains

A critique is presented of the quantitative model for the magnetic moment of pseudo-single domain grains (hypothetical magnetite grains larger than the critical size threshold for single domain behavior, yet also difficult to demagnetize), derived by Stacey and Banerjee (1974). Evidence from theoretical studies in micromagnetics demonstrates that the spin orientations in such grains are too complex to permit ready prediction of the magnetic moments. However, this limitation in the theory may be overcome by experiments involving rare earth-cobalt alloys and yttrium iron garnet crystals; these studies have suggested that surface anisotropy is the predominant cause of the high coercivity of pseudo-single domain grains.

Banerjee, S. K.↗
NASA NTRS1982

Review of corrosion causes and corrosion control in a technical facility

Causes of corrosion of metals and their alloys are reviewed. The corrosion mechanism is explained by electrochemical reaction theory. The causes and methods of controlling of both physiochemical corrosion and biological corrosion are presented. Factors which influence the rate of corrosion are also discussed.

Charng, T.↗
NASA NTRS1987

A thermodynamic prediction for microporosity formation in aluminum-rich Al-Cu alloys

A computer model is used to predict the formation and degree of microporosity in a directionally solidified Al-4.5 wt pct Cu alloy, considering the interplay between solidification shrinkage and gas porosity. Macrosegregation theory is used to determine the local pressure within the interdendritic liquid. Results show interdendritic porosity for initial hydrogen contents in the 0.03-1 ppm range, and none below contents of 0.03. An increase in either the thermal gradient or the solidification rate is show to decrease the amount of interdendritic porosity.

Poirier, D. R.↗
NASA NTRS1995

Measurements of the Viscosity of the Undercooled Melts Under the Conditions of Microgravity and Supporting MHD Calculations

This report covers the work to support the measurement of the surface tension and viscosity of undercooled metals with the TEMPUS as a part of the IML-2 mission. This work consisted of two parts. First was the ground-based research program, whose purpose was to establish the feasibility of the flight program and to establish the knowledge base necessary to plan a successful flight program. Analytical calculations established a fundamental understanding of the problem, and then a more rigorous program of numerical calculations was employed in the development of the experimental program. The second part of the covered research was the actual flight program, developed in close collaboration with Prof. Egry. A metal sphere was levitated and melted, and then set oscillating by 'squeezing' it with the magnetic field. The droplet's oscillations were recorded on videotape and digital image analysis was employed in reduction of the data. The experiment was successful because surface tension measurements were obtained for the gold and gold-copper alloy samples. This data provides unique experimental evidence in support of theories about electromagnetic levitation on the ground. Because of unforeseen difficulties with stability of liquid samples in TEMPUS, the viscosity measurements were not possible, but the data collection and analysis techniques were well proven in this mission. Further research is being conducted regarding the measurement of viscosity by this technique.

Szekely, Julian↗
NASA NTRS1999

Interaction of Porosity with an Advancing Solid/Liquid Interface: a Real-Time Investigation

Problems associated with formation of porosity during solidification continue to have a daily impact on the metal forming industry. Several past investigations have dealt with the nucleation and growth aspects of porosity. However, investigations related to the interaction of porosity with that of a solidification front has been limited mostly to organic analogues. In this paper we report on real time experimental observations of such interactions in metal alloys. Using a state of the art X-Ray Transmission Microscope (XTM) we have been able to observe and record the dynamics of the interaction. This includes distortion of the solid/liquid interface near a poro.sity, solute segr,egation patterns surrounding a porosity and the change in shape of the porosity during interaction with an advancing solid/liquid interface. Results will be presented for different Al alloys and growth conditions. The experimental data will be compared to theory using a recently developed 2D numerical model. The model employs a finite difference approach where the solid/liquid interface is defined through the points at which the interface intersects the grid lines. The transport variables are calculated at these points and the motion of the solidification front is determined by the magnitude of the transport variables. The model accounts for the interplay of the thermal and solutal field and the influence of capilarity to predict the shape of the solid/liquid interface with time in the vicinity of porosity. One can further calculate the perturbation of the solutal field by the presence of porosity in the melt.

Sen, S.↗
NASA NTRS2011

Crack Growth Behavior in the Threshold Region for High Cyclic Loading

The present studies show that fanning in the threshold regime is likely caused by other factors than a plastic wake developed during load shedding. The cause of fanning at low R-values is a result of localized roughness, mainly formation of a faceted crack surface morphology , plus crack bifurcations which alters the crack closure at low R-values. The crack growth behavior in the threshold regime involves both crack closure theory and the dislocation theory of metals. Research will continue in studying numerous other metal alloys and performing more extensive analysis, such as the variation in dislocation properties (e.g., stacking fault energy) and its effects in different materials.

Forman, R.↗
NASA NTRS1989

High temperature inelastic deformation under uniaxial loading - Theory and experiment

The elevated-temperature uniaxial inelastic deformation behavior of an Ni-base alloy, B1900 + Hf, is investigated by performing isothermal tensile, creep, cyclic, stress relaxation, and thermomechanical fatigue tests. The range of strain rates examined is from 10 to the -7th to 100 per sec, while the test temperatures range from 25 to 1093 C. This extensive constitutive data base has been used for evaluating the unified constitutive models of Bodner and Partom (1972) and of Walker (1972) which apply for the small-strain regime. Comparison of test results with independent model predictions indicates good agreement over a broad range of loading conditions, demonstrating the applicability of the unified-constitutive-equation approach for describing the strongly nonlinear and temperature-dependent response of meals under a wide range of deformation and thermal histories. Thus the results give confidence that the unified approach is an effective and efficient approach in which complex history-dependent thermoviscoplastic flow can be represented within a single inelastic strain-rate term.

Chan, K. S.↗
NASA NTRS2001

Dendritic Alloy Solidification Experiment (DASE)

A space experiment, and supporting ground-based research, is proposed to study the microstructural evolution in free dendritic growth from a supercooled melt of the transparent model alloy succinonitrile-acetone (SCN-ACE). The research is relevant to equiaxed solidification of metal alloy castings. The microgravity experiment will establish a benchmark for testing of equiaxed dendritic growth theories, scaling laws, and models in the presence of purely diffusive, coupled heat and solute transport, without the complicating influences of melt convection. The specific objectives are to: determine the selection of the dendrite tip operating state, i.e. the growth velocity and tip radius, for free dendritic growth of succinonitrile-acetone alloys; determine the growth morphology and sidebranching behavior for freely grown alloy dendrites; determine the effects of the thermal/solutal interactions in the growth of an assemblage of equiaxed alloy crystals; determine the effects of melt convection on the free growth of alloy dendrites; measure the surface tension anisotropy strength of succinon itrile -acetone alloys establish a theoretical and modeling framework for the experiments. Microgravity experiments on equiaxed dendritic growth of alloy dendrites have not been performed in the past. The proposed experiment builds on the Isothermal Dendritic Growth Experiment (IDGE) of Glicksman and coworkers, which focused on the steady growth of a single crystal from pure supercooled melts (succinonitrile and pivalic acid). It also extends the Equiaxed Dendritic Solidification Experiment (EDSE) of the present investigators, which is concerned with the interactions and transients arising in the growth of an assemblage of equiaxed crystals (succinonitrile). However, these experiments with pure substances are not able to address the issues related to coupled heat and solute transport in growth of alloy dendrites.

Beckermann, C.↗
NASA NTRS1989

Morphological transitions in the rapid solidification regime - A re-examination of the fundamental validity of the absolute stability concept of Mullins and Sekerka

The validity of the notion of absolute stability (AS) of a planar solid-liquid interface, proposed by Mullins and Sekerka (M-S, 1964), was tested using experimental data obtained for a number of dilute Ag-Cu and Sn-In alloys and for ultrahigh-purity succinonitrile. It is shown that the restriction applied by the M-S theory is satisfied during the steady-state planar solidification in an undercooled melt, provided the undercooling is quite small. The findings obtained on the Ag-Cu and Sn-In alloys are compared with early measurements by Davis and Fryzuk (1971) in dilute Sn-In alloys with 25 to 400 ppm additions of In.

Laxmanan, V.↗