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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

High-Temperature, Low-Cycle Fatigue of Copper-Base Alloys for Rocket Nozzles. Part 1: Data Summary for Materials Tested in Prior Programs

A more detailed analysis of the results obtained in 188 previously reported low-cycle fatigue tests of various candidate materials for regeneratively-cooled, reusable rocket nozzle liners was reported. Plots of load range versus cycles were reported for each test along with a stress-strain hysteresis loop near half-life. In addition, a summary table was provided to compare N5 (cycles to a five percent load range drop) and Nf (cycles to complete specimen separation) values for each test.

Conway, J. B.↗
NASA NTRS1982

High temperature low cycle fatigue mechanisms for nickel base and a copper base alloy

Damage mechanisms were studied in Rene' 95 and NARloy Z, using optical, scanning and transmission in microscopy. In necklace Rene' 95, crack initiation was mainly associated with cracking of surface MC carbides, except for hold time tests at higher strain ranges where initiation was associated more with a grain boundary mechanism. A mixed mode of propagation with a faceted fracture morphology was typical for all cycle characters. The dependence of life on maximum tensile stress can be demonstrated by the data falling onto three lines corresponding to the three tensile hold times, in the life against maximum tensile stress plot. In NARloy Z, crack initiation was always at the grain boundaries. The mode of crack propagation depended on the cycle character. The life decreased with decreasing strain rate and with tensile holds. In terms of damage mode, different life prediction laws may be applicable to different cycle characters.

Shih, C. I.↗
NASA NTRS1984

On Heat-Treatable Copper-Chromium Alloy, 1

A mother alloy of 10% Cr and 90% Cu was prepared by sintering. This was alloyed with the Cu melt and Cu-Cr alloys containing about 0.5% Cr was obtained. These alloys could be deformed easily in both the hot and cold states. By measuring the hardness change, age-hardening properties of cast alloys were studied, which were quenched from 950 deg and aged at 300 to 700 deg for 1 hour. The maximum hardness was obtained with the tempering temperature of 500 deg. For the temperature of solution-treatment, 950 deg was insufficient and that above 1000 deg necessary. For the tempering time, a treatment at 500 deg for 1 hr. or at 450 deg for 3 hrs. yielded the maximum hardness. As for the properties for electrical conductors, 3 kinds of wires (diam. 2 mm.) were made: (1) after cold-drawn to 2 mm., solution-treated, quenched, and then tempered (500 deg, 1 hr.); (2) after quenching, cold-drawn (75% reduction) to 2 mm. and tempered (500 deg, 1 hr.); and (3) after quenching, cold-drawn (81%) to intermediate diameter, tempered (500 deg, 1 hr.) and then cold-drawn (88%) again. Properties obtained for the 3 kinds, respectively, were as follows: conductivity 91, 90, and 86%. Tensile strength and strength for electrical conductivity are given.

Koda, S.↗
NASA NTRS1985

Initial aging phenomena in copper-chromium alloys

The effects of quenching and aging temperatures on the initial aging curves of Cu-Cr alloy were examined mainly by means of electrical resistivity measurements. Three Cu-Cr alloy specimens having 0.24, 0.74, and 1.0% Cr were solution-treated at 950-1050 C, quenched into ice-water, and subsequently aged at 300-500 C. The results were as follows: (1) At the very early stage of aging (within about 30 sec), an abrupt decrease of resistivity with lowering aging tempratures. (T sub A) and rising solution temperatures (T sub S) was observed at (T sub A) up to about 400 C. In contrast, a transient increase of resistivity with rising T sub A and lowering T sub S was observed at T sub A from about 450 to 500 C. These phenomena seem to be caused by a rapid formation of solute clusters and the reversion of clusters formed during quenching, which are enhanced by quenched-in vacancies, respectively. (2) The amount of precipitation increased at the latter stage of aging with rising T sub S and T sub A as generally expected, where T sub S was not so high as to form secondary defects. (3) As a result, the initial aging phenomena in Cr-Cr alloy were revealed to be complicated against expectations. This was considered to be due to the migration energy of vacancies so larger in Cu-base.

Suzuki, H.↗
NASA NTRS2005

Lifing of Engine Components

The successful development of advanced aerospace engines depends greatly on the capabilities of high performance materials and structures. Advanced materials, such as nickel based single crystal alloys, metal foam, advanced copper alloys, and ceramics matrix composites, have been engineered to provide higher engine temperature and stress capabilities. Thermal barrier coatings have been developed to improve component durability and fuel efficiency, by reducing the substrate hot wall metal temperature and protecting against oxidation and blanching. However, these coatings are prone to oxidation and delamination failures. In order to implement the use of these materials in advanced engines, it is necessary to understand and model the evolution of damage of the metal substrate as well as the coating under actual engine conditions. The models and the understanding of material behavior are utilized in the development of a life prediction methodology for hot section components. The research activities were focused on determining the stress and strain fields in an engine environment under combined thermo-mechanical loads to develop life prediction methodologies consistent with the observed damage formation of the coating and the substrates.

Source record↗
NASA NTRS2007

Comparison of GRCop-84 to Other High Thermal Conductive Cu Alloys

The mechanical properties of five copper alloys (GRCop-84, AMZIRC, GlidCop Al-15, Cu-1Cr-0.1Zr, Cu-0.9Cr) competing in high temperature, high heat flux applications such as rocket nozzles, were compared. Tensile, creep, thermal expansion, and compression tests are presented. Tests were done on as-received material, and on material which received a simulated brazing heat treatment at 935 C. The 935 C heat treatment weakened AMZIRC, Cu-1Cr-0.1Zr, and Cu-0.9Cr, and the strength of as-received AMZIRC dropped precipitously as test temperatures exceeded 500 C. The properties of GlidCop Al-15 and GRCop-84 were not significantly affected by the 935 C heat treatment. Thus GRCop-84 is better than AMZIRC, Cu-1Cr-0.1Zr, and Cu-0.9Cr at temperatures greater than 500 C. Ductility was lowest in GlidCop Al-15 and Cu-0.9Cr. The creep properties of GRCop-84 were superior to those of brazed AMZIRC, Cu-1Cr-0.1Zr, and Cu-0.9Cr. At equivalent rupture life and stress, GRCop-84 had a 150 C temperature advantage over brazed AMZIRC; for equivalent rupture life and temperature GRCop-84 was two times stronger. The advantages of GRCop-84 over GlidCop Al-15 associated with ease of processing were confirmed by GlidCop s marginal ductility. In the post brazed condition, GRCop-84 was found to be superior to the other alloys due to its greater strength and creep resistance (compared to AMZIRC, Cu-1Cr-0.1Zr, and Cu-0.9Cr) and ductility (compared to GlidCop Al-15)

deGroh, Henry C., III↗
NASA NTRS1983

Containerless electromagnetic levitation melting of Cu-Fe and Ag-Ni alloys

The feasibility of producing silver or copper alloys containing finely dispersed nickel or iron particles, respectively, by utilizing containerless electromagnetic levitation casting techniques was investigated. A levitation coil was designed to successfully levitate and melt a variety of alloys including Nb-Ge, Cu-Fe, Fe-C, and Ag-Ni. Samples of 70 Cu-30 Fe and 80 Ag-20 Ni (atomic %), prepared by mechanical pressing of the constituent powders, were levitated and heated either to the solid plus liquid range of the alloys or to the fully liquid region. The samples were then solidified by passing helium gas into the bell jar or they were dropped into a quenching oil. The structure of the samples which were heated to the solid plus liquid range consists of uniform distribution of Fe or Ni particle in their respective matrices. A considerable amount of entrapped gas bubbles were contained. Upon heating for longer periods or to higher temperatures, the bubbles coalesced and burst, causing the samples to become fragmented and usually fall out of the coil.

Abbaschian, G. J.↗
NASA NTRS2006

Observations of a Cast Cu-Cr-Zr Alloy

Prior work has demonstrated that Cu-Cr-Nb alloys have considerable advantages over the copper alloys currently used in regeneratively cooled rocket engine liners. Observations indicated that Zr and Nb have similar chemical properties and form very similar compounds. Glazov and Zakharov et al. reported the presence of Cr2Zr in Cu-Cr-Zr alloys with up to 3.5 wt% Cr and Zr though Zeng et al. calculated that Cr2Zr could not exist in a ternary Cu-Cr-Zr alloy. A cast Cu-6.15 wt% Cr-5.25 wt% Zr alloy was examined to determine if the microstructure developed would be similar to GRCop-84 (Cu-6.65 wt% Cr-5.85 wt% Nb). It was observed that the Cu-Cr-Zr system did not form any Cr2Zr even after a thermal exposure at 875 C for 176.5 h. Instead the alloy consisted of three phases: Cu, Cu5Zr, and Cr.

Ellis, David L.↗
NASA NTRS1983

Transmission electron microscopy characterization of microstructural features of Al-Li-Cu alloys

A transmission electron microscopy (TEM) examination of aluminum-lithium-copper alloys was conducted. The principal purpose is to characterize the nature, size, and distribution of stringer particles which result from the powder metallurgy (P/M) processing of these alloys. Microstructural features associated with the stringer particles are reported that help explain the stress corrosion susceptibility of the powder metallurgy-processed Al-Li-Cu alloys. In addition, matrix precipitation events are documented for a variety of heat treatments and process variations. Hot rolling is observed to significant alter the nature of matrix precipitation, and the observations are correlated with concomitant mechanical property variations.

Avalos-Borja, M.↗
NASA NTRS2007

Comparison of GRCop-84 to Other Cu Alloys with High Thermal Conductivities

The mechanical properties of six highly conductive copper alloys, GRCop-84, AMZIRC, GlidCop Al-15, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z were compared. Tests were done on as-received hard drawn material, and after a heat treatment designed to simulate a brazing operation at 935 C. In the as-received condition AMZIRC, GlidCop Al-15, Cu- 1Cr-0.1Zr and Cu-0.9Cr had excellent strengths at temperatures below 500 C. However, the brazing heat treatment substantially decreased the mechanical properties of AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z. The properties of GlidCop Al-15 and GRCop-84 were not significantly affected by the heat treatment. Thus there appear to be advantages to GRCop-84 over AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z if use or processing temperatures greater than 500 C are expected. Ductility was lowest in GlidCop Al-15 and Cu-0.9Cr; reduction in area was particularly low in GlidCop Al-15 above 500 C, and as- received Cu-0.9Cr was brittle between 500 and 650 C. Tensile creep tests were done at 500 and 650 C; the creep properties of GRCop-84 were superior to those of brazed AMZIRC, Cu-1Cr- 0.1Zr, Cu-0.9Cr, and NARloy-Z. In the brazed condition, GRCop-84 was superior to the other alloys due to its greater strength and creep resistance (compared to AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z) and ductility (compared to GlidCop Al-15).

deGroh, Henry C., III↗
NASA NTRS1973

Mechanical property determination of high conductivity metals and alloys

Pertinent mechanical properties of three high conductivity metals and alloys; namely, vacuum hot pressed grade S-200E beryllium, OFHC copper and beryllium-copper alloy no. 10 were determined. These materials were selected based on their possible use in rocket thrust chamber and nozzle hardware. They were procured in a form and condition similar to that which might be ordered for actual hardware fabrication. The mechanical properties measured include (1) tension and compression stress strain curves at constant strain rate (2) tensile and compressive creep, (3) tensile and compressive stress-relaxation behavior and (4) elastic properties. Tests were conducted over the temperature range of from 75 F to 1600 F. The resulting data is presented in both graphical and tabular form.

Harrod, D. L.↗
NASA NTRS2005

Characterization of Cold Sprayed CuCrAl Coated GRCop-84 Substrates for Reusable Launch Vehicles

An advanced Cu-8(at.%)Cr-4%Nb alloy developed at NASA's Glenn Research Center, and designated as GRCop-84, is currently being considered for use as combustor liners and nozzles in NASA's future generations of reusable launch vehicles (RLVs). Despite the fact that this alloy has superior mechanical and oxidation properties compared to many commercially available copper alloys, it is felt that its high temperature and environmental resistance capabilities can be further enhanced with the development and use of suitable coatings. Several coatings and processes are currently being evaluated for their suitability and future down selection. A newly developed CuCrAl has shown excellent oxidation resistance compared to current generation Cu-Cr coating alloys. Cold spray technology for depositing the CuCrAl coating on a GRCop-84 substrate is currently being developed under NASA's Next Generation Launch Technology (NGLT) Propulsion Research and Technology (PR&T) project. The microstructures, mechanical and thermophysical properties of overlay coated GRCop-84 substrates are discussed.

Raj, S . V.↗
NASA NTRS1978

Braze alloy spreading on steel

Scanning electron microscopy (SEM) and Auger electron microscopy (AEM) were employed to observe elemental surface decomposition resulting from the brazing of a copper-treated steel. Two types of steel were used for the study, stainless steel (treated with a eutectic silver-copper alloy), and low-carbon steel (treated with pure copper). Attention is given to oxygen partial pressure during the processes; a low enough pressure (8 x 10 to the -5th torr) was found to totally inhibit the spreading of the filler material at a fixed heating cycle. With both types of steel, copper treatment enhanced even spreading at a decreased temperature.

Siewert, T. A.↗
NASA NTRS1972

Process for the Production of Star Tracklng [Tracking] Reticles

A method for the production of reticles, particularly those for use in outer space, wherein the product is a quartz base coated with highly adherent layers of chromium, chromium-silver, and silver vacuum deposited through a mask, and then coated with an electrodeposit of copper from a copper sulfate solution followed by an electrodeposit of black chromium. The masks are produced by coating a beryllium-copper alloy substrate with a positive working photoresist, developing the photoresist according to a pattern to leave a positive mask, plating uncoated areas with gold, removing the photoresist, coating the substrate with a negative working photoresist, developing the negative working photoresist to expose the base metal of the pattern, and chemically etching the unplated side of the pattern to produce the mask. The mask produced is then used in the vacuum deposition of: (1) chromium metal on the surface of a quartz base to obtain a highly adherent quartz-chromium interface; (2) silver on the chromium deposit, during the final stage of chromium deposit, to produce a silver chromium alloy layer; and (3) silver onto the surface of the alloy layer. The coated quartz base is then coated by electroplating utilizing an acid copper deposit followed by a black chromium electrodeposit to produce the product of the present invention.

Smith, Wade O.↗
DOE OSTI2024

Aluminum Ultra-conductors for Energy-Efficient Aerospace Busbar Applications (Abstract)

In this project, we will develop aluminum ultra-conductors with graphene additives demonstrating enhanced electrical conductivity at 90 °C compared to electric grade aluminum alloy AA1100 (43% IACS at 90 °C). While ultra-conductivity has been developed in copper and copper alloys, it is yet to be reported extensively in aluminum-based materials. This project will scale initial work done at PNNL on aluminum ultra-conductors using shear-assisted processing and extrusion (ShAPETM), a novel solid phase processing technique. Ultra-conductors are an emerging class of composites, comprised of a metal substrate with small quantities of nanocrystalline additives such as graphene or carbon nanotubes that demonstrate enhanced conductivity at relevant operating temperatures. Aluminum ultra-conductors can improve efficiency and power density while reducing the demand for copper in a wide range of applications, such as power transmission cables and electric motors. Busbars are an important component in aerospace systems that require lightweight and high-current power distribution including both future electric vertical take-off and landing (eVTOL) aircrafts and current aircraft electrical systems. We will accelerate aluminum ultra-conductor composite formulation development using combinatorial synthesis and testing methods aided by process/microstructure modeling, developed previously at PNNL. Eaton will test the properties of the ShAPE aluminum ultra-conductor feedstock (used to make the busbars) in relevant operating conditions (20 – 90 °C), predict the improvement in busbar performance when manufactured with ultra-conductors over commercial conductors (such as AA1100), and perform technoeconomic analysis to evaluate the potential for commercialization of ShAPE aluminum ultra-conductors. The project is expected to have a budget of $\$375$K, with $\$300$K in federal funding and $\$75$K in-kind cost-share contribution from Eaton over a period of performance of 24 months. Of the $\$300$K of federal funds, $\$140$K is allocated for CRADA activities that generate intellectual property (IP), and the remaining $\$160$K is reserved for modeling, material testing, characterization, travel, and reporting-related activities.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Clarifying the formation of equiaxed grains and microstructural refinement in the additive manufacturing of Ti-Cu

Controlling microstructural evolution in metallic additive manufacturing (AM) is difficult, especially in producing refined as-built grains instead of coarse, directional grains. Traditional solutions involve adding inoculants to AM feedstocks, but titanium (Ti) alloys cannot employ this approach without producing detrimental secondary phases. Ti-Cu (Ti-copper) alloys offer a solution through constitutional supercooling and/or solid state thermal cycling under AM conditions. This work analyzes a compositionally graded directed energy deposition (DED) Ti-Cu build, single-melt laser tracks, and dilatometric heat treatments to evaluate if, when, and by what mechanism(s) microstructural refinement occurs. Refinement by inoculation of unmelted powder particles was also considered. Constitutional supercooling produced no net microstructural refinement as any equiaxed dendrites which form are remelted with new deposition. This finding agreed with solidification modeling of powder bed fusion-laser beam (PBF-LB) and DED builds. Solid state thermal cycling refined microstructures only during ex-situ dilatometric heat treatments, suggesting build parameter optimization is needed to achieve refinement in-situ. Accidental heterogeneous nucleation on unmelted Ti powder, originating from the different thermophysical properties of Ti and Cu, provided the most significant microstructural refinement. This work systematically assesses the microstructural refinement mechanisms of Ti-Cu in AM builds and offers insights into microstructural control in eutectoid alloys.

36 MATERIALS SCIENCE↗