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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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106 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Effect of Sintering on Mechanical and Physical Properties of Plasma-Sprayed Thermal Barrier Coatings

The effect of sintering on mechanical and physical properties of free-standing plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings (TBCs) was determined by annealing them at 1316 C in air. Mechanical and physical properties of the TBCs, including strength, modes I and II fracture toughness, elastic modulus, Poisson s response, density, microhardness, fractography, and phase stability, were determined at ambient temperature as a function of annealing time ranging from 0 to 500 h. All mechanical and physical properties, except for the amount of monoclinic phase, increased significantly in 5 to 100 h and then reached a plateau above 100 h. Annealing resulted in healing of microcracks and pores and in grain growth, accompanying densification of the TBC s body due to the sintering effect. However, an inevitable adverse effect also occurred such that the desired lower thermal conductivity and good expansivity, which makes the TBCs unique in thermal barrier applications, were degraded upon annealing. A model was proposed to assess and quantify all the property variables in response to annealing in a normalized scheme. Directionality of as-sprayed TBCs appeared to have an insignificant effect on their properties, as determined via fracture toughness, microhardness, and elastic modulus measurements.

Choi, Sung R.↗
NASA NTRS2006

Burst Testing and Analysis of Superalloy Disks With a Dual Grain Microstructure

Elastic-plastic finite element analyses of room temperature burst tests on four superalloy disks were conducted and reported in this paper. Two alloys, Rene 104 (General Electric Aircraft Engines) and Alloy 10 (Honeywell Engines & Systems), were studied. For both alloys an advanced dual microstructure disk, fine grain bore and coarse grain rim, were analyzed and compared with conventional disks with uniform microstructures, coarse grain for Rene 104 and fine grain for Alloy 10. The analysis and experimental data were in good agreement up to burst. At burst, the analysis underestimated the speed and growth of the Rene 104 disks, but overestimated the speed and growth of the Alloy 10 disks. Fractography revealed that the Alloy 10 disks displayed significant surface microcracking and coalescence in comparison to Rene 104 disks. This phenomenon may help explain the differences between the Alloy 10 disks and the Rene 104 disks, as well as the observed deviations between analytical and experimental data at burst.

Gayda, John↗
NASA NTRS2010

Failure Analysis of Fractured Poppet from Space Shuttle Orbiter Flow Control Valve

This slide presentation reviews the failure analysis of a fractured poppet from a flow control valve (FCV) used on the space shuttle. This presentation has focused on the laboratory analysis of the failed hardware. The use of Scanning electron fractography during the investigation led to the conclusion that the poppet failed due to fatigue cracking that, most likely, occurred under changing loading conditions. The initial investigation led to a more thorough test of poppets that had been retired, this testing led to the conclusion that the thumbnail cracks in the flight hardware had existed for the life of the shuttle program. This led to a program to develop an eddy current technique that was capable of detecting small very tight cracks.

Russell, Richard↗
NASA NTRS2011

Small Scale Turbopump Manufacturing Technology and Material Processes

As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.

Alvarez, Erika↗
NASA NTRS2012

Characterizing Delamination Migration in Carbon/Epoxy Tape Laminates

A new test method is presented for the purpose of investigating migration of a delamination between neighboring ply interfaces in fiber-reinforced, polymer matrix tape laminates. The test is a single cantilever beam configuration consisting of a cross-ply laminate with a polytetrafluoroethylene (PTFE) insert implanted at the mid-plane and spanning part way along the length of the specimen. The insert is located between a 0-degree ply (specimen length direction) and a stack of four 90-degree plies (specimen width direction). The specimen is clamped at both ends onto a rigid baseplate and is loaded on its upper surface via a piano hinge. Tests were conducted with the load-application point located on the intact portion of the specimen in order to initiate delamination growth onset followed by migration of the delamination to a neighboring 90/0 ply interface by kinking through the 90- degree ply stack. Varying this position was found to affect the distance relative to the load-application point at which migration initiated. In each specimen, migration initiated by a gradual transition of the delamination at the 0/90 interface into the 90- degree ply stack. In contrast, transition of the kinked crack into the 90/0 interface was sudden. Fractography of the specimens indicated that delamination prior to migration was generally mixed mode-I/II. Inspection of the kink surface revealed mode-I fracture. In general, use of this test allows for the observation of the growth of a delamination followed by migration of the delamination to another ply interface, and should thus provide a means for validating analyses aimed at simulating migration.

Ratcliffe, James G.↗
NASA NTRS2013

A Test for Characterizing Delamination Migration in Carbon/Epoxy Tape Laminates

A new test method is presented for the purpose of investigating migration of a delamination between neighboring ply interfaces in fiber-reinforced, polymer matrix tape laminates. The test is a single cantilever beam configuration consisting of a cross-ply laminate with a polytetrafluoroethylene insert implanted at the mid-plane and spanning part way along the length of the specimen. The insert is located between a 0- degree ply (specimen length direction) and a stack of four 90-degree plies (specimen width direction). The specimen is clamped at both ends onto a rigid baseplate and is loaded on its upper surface via a piano hinge. Tests were conducted with the load-application point located on the intact portion of the specimen in order to initiate delamination growth onset followed by migration of the delamination to a neighboring 90/0 ply interface by kinking through the 90-degree ply stack. Varying this position was found to affect the distance relative to the load-application point at which migration initiated. In each specimen, migration initiated by a gradual transition of the delamination at the 0/90 interface into the 90-degree ply stack. In contrast, transition of the kinked crack into the 90/0 interface was sudden. Fractography of the specimens indicated that delamination prior to migration was generally mixed mode-I/II. Inspection of the kink surface revealed mode-I fracture. In general, use of this test allows for the observation of the growth of a delamination followed by migration of the delamination to another ply interface, and should thus provide a means for validating analyses aimed at simulating migration.

Ratcliffe, James G.↗
NASA NTRS2015

Correlation of Electrical Resistance to CMC Stress-Strain and Fracture Behavior Under High Heat-Flux Thermal and Stress Gradients

Because SiCSiC ceramic matrix composites (CMCs) are under consideration for use as turbine engine hot-section components in extreme environments, it becomes necessary to investigate their performance and damage morphologies under complex loading and environmental conditions. Monitoring of electrical resistance (ER) has been shown as an effective tool for detecting damage accumulation of woven melt-infiltrated SiCSiC CMCs. However, ER change under complicated thermo-mechanical loading is not well understood. In this study a systematic approach is taken to determine the capabilities of ER as a relevant non-destructive evaluation technique for high heat-flux testing, including thermal gradients and localized stress concentrations. Room temperature and high temperature, laser-based tensile tests were conducted in which stress-dependent damage locations were determined using modal acoustic emission (AE) monitoring and compared to full-field strain mapping using digital image correlation (DIC). This information is then compared with the results of in-situ ER monitoring, post-test ER inspection and fractography in order to correlate ER response to convoluted loading conditions and damage evolution.

electrical resistance↗
NASA NTRS2016

Materials Characterization of Electron Beam Melted Ti-6Al-4V

An in-depth material characterization of Electron Beam Melted (EBM) Ti-6Al-4V material has been completed on samples fabricated on an ARCAM A2X EBM machine. The specimens were fabricated under eight separate builds with the material divided into two lots for material testing purposes. Hot Isostatic Pressing (HIP) was utilized to close porosity from fabrication and also served as a material heat treatment to obtain the desired microstructure. The changes in the microstructure and chemistry from the powder to pre-HIP and post-HIP material have been analyzed. Several nondestructive evaluation (NDE) techniques were utilized to characterize the samples both before and after HIP. The test matrix included tensile, high cycle fatigue, low cycle fatigue, fracture toughness, and fatigue crack growth at cryogenic, room, and elevated temperatures. The mechanical properties of the EBM Ti-6Al-4V are compared to conventional Ti-6Al-4V in the annealed condition. Fractography was performed to determine failure initiation site. The EBM Ti-6Al-4V had similar or superior mechanical properties compared to conventionally manufactured Ti-6Al-4V.

Titanium↗
NASA NTRS2024

Tensile Behavior and High-Cycle Fatigue Durability of a SiC/SiC Ceramic-Matrix Composite Without and With Simulated Cooling Holes

High-cycle fatigue (HCF) behavior of a melt-infiltrated, prepreg SiC/SiC composite was investigated using specimens without and with simulated cooling holes at 816 and 1,316 °C. The ceramic-matrix composite (CMC) material used for this study was fabricated by GE Aviation and had a ply configuration of [0/90/0] 3 . HCF tests were conducted with an R-ratio of 0.6 and a cyclic frequency of 30 Hz. Maximum tensile gross-section stresses used in the HCF tests ranged from 152 to 359 MPa. Runout in HCF was defined as 30 million cycles (278 h) at both temperatures. Monotonic tensile tests were conducted at room temperature (RT) on as-received CMC specimens and on HCF runout specimens without and with holes to determine residual tensile strengths. Digital image correlation (DIC) and acoustic emission (AE) techniques were used to monitor progression of damage in RT tensile tests on specimens without and with holes. Fractography was performed on a limited number of specimens without and with holes to determine morphology of fracture surfaces. Representative RT stress-strain behavior, elevated temperature HCF behavior at the two temperatures, and RT residual tensile strengths of HCF runout specimens are documented in this report. Select examples of DIC and AE data from RT tensile tests on specimens without and with holes and typical features observed on fracture surfaces of specimens tested under tensile and HCF conditions are also discussed.

Ceramic matrix composite↗
NASA NTRSDate not supplied

Effect of Tungsten L-PBF Feedstock Modification on Performance in Bending

Additively manufactured tungsten is a candidate refractory material for high-temperature aerospace and nuclear fusion/fission applications. The printability of pure tungsten is challenged by cracking defects arising from the metal’s high ductile-to-brittle transition temperature and low solubility of interstitial impurities. Furthermore, the cast microstructure inherent to the laser powder bed fusion (L-PBF) process has limited strength compared to worked microstructures common in wrought tungsten. Aside from process-related techniques to mitigate defects and increase strength (e.g., heated build chambers, multi-laser systems, low oxygen environmental control, etc.), micro-alloying additions can positively influence tungsten printability. In this work, pure tungsten L-PBF feedstock was modified with 1 wt% additions of ceramic compound nano-powders. Wrought and printed bars were evaluated in four-point bending. Flexural strength and fractography were primary means of comparison to assess the effect of the feedstock modification on printed tungsten mechanical performance.

Tungsten-based alloys↗
NASA NTRSDate not supplied

Aluminum to Stainless-Steel Joints for Cryogenic Applications

Aluminum to stainless-steel joints are necessary for cryogenic applications such as cryogenic fluid management and combustion devices. Supplemental development in this area was required for a test program at NASA Marshall Space Flight Center (MSFC) of an Al6061-RAM2 additively manufacturing liquid rocket nozzle. The test program identified a risk for installing stainless-steel fluid fittings to aluminum manifolds. To address this, a literature search was completed for various joint designs, and three designs were down selected to be cryogenic pressure cycle tested at MSFC. The test pieces were subsequently burst tested with ambient temperature water. This paper provides an overview of the literature review, down selected designs, test setup, test results, and fractography. The test results informed design decisions for the Al6061-RAM2 nozzle, and the recommended design proved to be a robust option with no notable issues identified during hot-fire testing.

Tessa M. Fedotowsky↗
NASA NTRS2026

Fatigue Life of Flow-Formed Aluminum 2195 and 6061 Alloys

The successful design and fabrication of metallic cryotanks for commercial aviation applications require lightweight, durable materials capable of withstanding high pressures and cryogenic temperatures through tens of thousands of thermomechanical refueling cycles. Flow forming is an advanced manufacturing technique that offers high-rate production and scalability for fabricating integrally stiffened cylinders suitable for cryotank applications. This work establishes the durability of flow-formed aluminum alloys by characterizing their fatigue life performance under conditions that mimic cryotank refueling cycles. Residual stresses in flow-formed aluminum-lithium (Al-Li) 2195-T6 cylinders were assessed using the contour method and found to be minimal. Fatigue life testing was conducted on flow-formed Al-Li 2195-T6 at room temperature and cryogenic temperatures (-321°F [-196°C]), with wrought Al-Li 2195-T6 serving as a baseline for comparison. Results showed that flow-formed materials exhibited fatigue performance comparable to or better than wrought materials, with no statistically significant differences observed between different specimen orientations relative to processing directions. Fractography revealed reduced delaminations in the flow-formed Al-Li 2195 samples as compared to wrought, indicating potential improvement to the microstructure that could result in improved service properties. Texture analysis using electron backscattered diffraction (EBSD) indicated recrystallization during heat treatment, potentially contributing to reduced delamination susceptibility. These findings demonstrating flow-formed material durability coupled with the high manufacturing efficiency of flow forming, makes flow forming an attractive process to produce aircraft cryotanks.

EBF3↗
NASA NTRS2015

Mechanical Properties of a High Lead Glass Used in the Mars Organic Molecule Analyzer

The elastic constants, strength, fracture toughness, slow crack growth parameters, and mirror constant of a high lead glass supplied as tubes and funnels were measured using ASTM International (formerly ASTM, American Society for Testing and Materials) methods and modifications thereof. The material exhibits lower Young's modulus and slow crack growth exponent as compared to soda-lime silica glass. Highly modified glasses exhibit lower fracture toughness and slow crack growth exponent than high purity glasses such as fused silica.

lead↗
NASA NTRS2017

Crack Growth Testing of an Aluminum Oxynitride (AlON) for International Space Station Kick Panes

The mechanical properties of an aluminum oxynitride supplied as ground beams and disks were measured using ASTM International (formerly American Society for Testing and Materials) standard test methods. The slow crack growth tests were complicated by a "short" finish that increased strength scatter. Refining of the finish by more material removal in the second stage of grinding or the use of uniaxial grinding as specified in ASTM C1499 might have avoided the issue. The structural design parameters are an elastic modulus of E = 319 GPa, Poisson's ratio of v = 0.26, a fracture toughness of KIvb(A) = 2.18 MPa/m, slow crack growth (SCG) parameter n = 36, and SCG parameter A = 1.96 x 10-11 m/s.(MPa/m)n. For a ground finish, the Weibull parameters are a mean modulus of m = 14.0 and characteristic strength of sigma theta = 250.2 MPa. The 2015 vintage material exhibits similar mechanical properties to a 2010 vintage billet. Indentation flaws were not sensitive to the inherent crack growth mechanisms of this material and produced misleading results.

strength↗
NASA NTRS2018

Fractographic Analysis of 60-Nitinol Bearing Races

Fracture surfaces on a failed bearing race made from 60-Nitinol (60 wt% Ni - 40 wt% Ti) were analyzed. The bearing had experienced excessive localized heat due to an issue during machining that may have resulted in dimensional distortion. However, the classical fracture features that were identified by scanning electron microscopy and the fracture origins coincided with high concentrations of TiC-based contamination. Lessons learned for processing and quality control are discussed. An attempt to use x-ray diffraction to directly measure residual stresses imparted from the required heat treatment is also discussed.

intermetallics↗