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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 NTRS1976

Influence of gaseous hydrogen on the mechanical properties of high temperature alloys

Tensile tests of six nickel-base and one cobalt-base alloy were conducted in 34.5 MN/sq m helium and hydrogen environments at temperatures from 297 K to 1,088 K. Mechanical properties tests of the nickel-base alloy MAR M-246 (Hf modified), in two cast conditions, were conducted in gaseous environments at temperatures from 297 K to 1,144 K and pressures from one atmosphere to 34.5 MN/sq m. The objective of this program was to obtain the mechanical properties of the various alloys proposed for use in space propulsion systems in a pure hydrogen environment at different temperatures and to compare with the mechanical properties in helium at the same conditions. All testing was conducted on solid specimens exposed to external gaseous pressure. Smooth and notched tensile properties were determined using ASTM tensile testing techniques, and creep-rupture life was determined using ASTM creep-rupture techniques. Low-cycle fatigue life was established by constant total strain and constant stress testing using smooth specimens and a closed-loop test machine.

Source record↗
NASA NTRS1938

Preliminary Fatigue Studies on Aluminum Alloy Aircraft Girders

Preliminary information on the complex subject of the fatigue strength of fabricated structural members for aircraft is presented in the test results obtained on several different types of airship girders subjected to axial tension and compression in a resonance fatigue machine. A description of this machine as well as numerous photographs of the fatigue failures are given. There is also presented an extended bibliography on the subject of fatigue strength.

Source record↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗
DOE OSTI2024

Microstructural effects on the rotating bending fatigue behavior of Ti–6Al–4V produced via laser powder bed fusion with novel heat treatments

The rotating bending fatigue (RBF) behavior (fully reversed, R = -1) of additively manufactured (AM) Ti–6Al–4V alloy produced via laser powder bed fusion (PBF-L) was investigated with respect to different microstructures achieved through novel heat treatments. The investigation herein seeks to elucidate the effect of microstructure by controlling variables that can affect fatigue behavior in Ti–6Al–4V, such as chemistry, porosity, and surface roughness. In order to control these variables, different hot isostatic pressing (HIP) treatments at 800 °C, 920 °C, and 1050 °C with a 920 °C temper were applied to three sets of Ti–6Al–4V cylinders that originated from the same PBF-L build, such that there were 30 tests per condition. After HIP treatment, the specimens were machined and tested. The highest runout stress was achieved after sub-β transus HIP at 800 °C for 2 h at 200 MPa of pressure. A significant drop in fatigue strength was attributed to large prior-β grains and grain boundary α resulting from super-β transus HIP treated specimens. In conclusion, for the sub-β transus HIP specimens, differences in fatigue strength were attributed to α lath thickness, relative dislocation density, and dislocation boundary strengthening.

36 MATERIALS SCIENCE↗
NASA NTRS1975

The detection of tightly closed flaws by nondestructive testing (NDT) methods

Liquid penetrant, ultrasonic, eddy current and X-radiographic techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens in integrally stiffened panel, and weld panel configurations. Fatigue cracks in integrally stiffened panels, lack-of-fusion in weld panels, and fatigue cracks in weld panels were the flaw types used for evaluation. A 2319 aluminum alloy weld filler rod was used for all welding to produce the test specimens. Forty seven integrally stiffened panels containing a total of 146 fatigue cracks, ninety three lack-of-penetration (LOP) specimens containing a total of 239 LOP flaws, and one-hundred seventeen welded specimens containing a total of 293 fatigue cracks were evaluated. Nondestructive test detection reliability enhancement was evaluated during separate inspection sequences in the specimens in the 'as-machined or as-welded', post etched and post proof loaded conditions. Results of the nondestructive test evaluations were compared to the actual flaw size obtained by measurement of the fracture specimens after completing all inspection sequences. Inspection data were then analyzed to provide a statistical basis for determining the flaw detection reliability.

Rummel, W. D.↗
DOE OSTI2022

Additive Manufacturing Flaw Assessment Methodology

An evolution fatigue data and flaw tolerance of components produced using the Powder Bed Fusion (PBF) Additive Manufacturing (AM) process is documented in this report. Initial differences in fatigue data for AM components compared to smooth bar fatigue data indicated a need for a more detailed analysis of AM data available in technical literature. The investigation was initiated to support the development of a fatigue analysis methodology for AM components to support the of codification of AM technology for pressure equipment. The project was initiated to collect and analyze stainless steel 304L and 316L AM fatigue test data and corresponding process and quality information to develop S-N and E-N based fatigue data representation. Additional AM fatigue test data including Inconel Ti-6-4 and aluminum alloys were also considered for comparison purposes Metallic AM parts tend to contain various forms of defects distributed throughout the part. If an AM part is subjected to fatigue loading in service, a fatigue analysis needs to be performed during the design process to ensure an acceptable service life for the part. Post-process machining and polishing do not to improve fatigue resistance in any significant degree. The low cycle fatigue regime is of particular interest to this project in support of flaw acceptance criteria currently under development by ASME’s BPTCS/BNCS. Internal defects become exposed as external surface defects during machining for the machining of the AM part to final dimensions. This implies that as long as inherent AM defects are within a controlled limit in terms of both size and distribution characteristics, the corresponding fatigue test data in terms of either S-N (stress life) or E-N (strain life) can be investigated and characterized to establish fatigue properties of AM parts for design and fatigue evaluation purposes. The resulting S-N or E-N curves and their scatter bands can be used to derive fatigue design allowable stress values by capturing the effects of distributed discontinuities within an acceptable limit.

36 MATERIALS SCIENCE↗
NASA NTRS2010

Effect of the Machining Processes on Low Cycle Fatigue Behavior of a Powder Metallurgy Disk

A study has been performed to investigate the effect of various machining processes on fatigue life of configured low cycle fatigue specimens machined out of a NASA developed LSHR P/M nickel based disk alloy. Two types of configured specimen geometries were employed in the study. To evaluate a broach machining processes a double notch geometry was used with both notches machined using broach tooling. EDM machined notched specimens of the same configuration were tested for comparison purposes. Honing finishing process was evaluated by using a center hole specimen geometry. Comparison testing was again done using EDM machined specimens of the same geometry. The effect of these machining processes on the resulting surface roughness, residual stress distribution and microstructural damage were characterized and used in attempt to explain the low cycle fatigue results.

Telesman, J.↗
NASA NTRS1979

Low-cost directionally-solidified turbine blades, volume 2

An endothermically heated technology was used to manufacture low cost, directionally solidified, uncooled nickel-alloy blades for the TFE731-3 turbofan engine. The MAR-M 247 and MER-M 100+Hf blades were finish processed through heat treatment, machining, and coating operations prior to 150 hour engine tests consisting of the following sequences: (1) 50 hours of simulated cruise cycling (high fatigue evaluation); (2) 50 hours at the maximum continuous power rating (stress rupture endurance (low cycle fatigue). None of the blades visually showed any detrimental effects from the test. This was verified by post test metallurgical evaluation. The specific fuel consumption was reduced by 2.4% with the uncooled blades.

Dennis, R. E.↗
NASA NTRS2001

Transverse Tension Fatigue Life Characterization Through Flexure Testing of Composite Materials

The transverse tension fatigue life of S2/8552 glass-epoxy and IM7/8552 carbon-epoxy was characterized using flexure tests of 90-degree laminates loaded in 3-point and 4-point bending. The influence of specimen polishing and specimen configuration on transverse tension fatigue life was examined using the glass-epoxy laminates. Results showed that 90-degree bend specimens with polished machined edges and polished tension-side surfaces, where bending failures where observed, had lower fatigue lives than unpolished specimens when cyclically loaded at equal stress levels. The influence of specimen thickness and the utility of a Weibull scaling law was examined using the carbon-epoxy laminates. The influence of test frequency on fatigue results was also documented for the 4-point bending configuration. A Weibull scaling law was used to predict the 4-point bending fatigue lives from the 3-point bending curve fit and vice-versa. Scaling was performed based on maximum cyclic stress level as well as fatigue life. The scaling laws based on stress level shifted the curve fit S-N characterizations in the desired direction, however, the magnitude of the shift was not adequate to accurately predict the fatigue lives. Furthermore, the scaling law based on fatigue life shifted the curve fit S-N characterizations in the opposite direction from measured values. Therefore, these scaling laws were not adequate for obtaining accurate predictions of the transverse tension fatigue lives.

OBrien, T. Kevin↗
NASA NTRS2002

Preliminary Study on Fatigue Strengths of Fretted Ti-48Al-2Cr-2Nb

The fatigue behavior (stress-life curve) of gamma titanium aluminide (Ti-48Al-2Cr-2Nb, atomic percent) was examined by conducting two tests: first, a fretting wear test with a fatigue specimen in contact with a typical nickel-based superalloy contact pad in air at temperatures of 296 and 823 K and second, a high-cycle fatigue test of the prefretted Ti-48Al-2Cr-2Nb fatigue specimen at 923 K. Reference high-cycle fatigue tests were also conducted with unfretted Ti-48Al-2Cr-2Nb specimens at 923 K. All Ti-48Al-2Cr-2Nb fatigue specimens were machined from cast slabs. The results indicate that the stress-life results for the fretted Ti-48Al-2Cr-2Nb specimens exhibited a behavior similar to those of the unfretted Ti-48Al-2Cr-2Nb specimens. The values of maximum stress and life for the fretted specimens were almost the same as those for the unfretted specimens. The resultant stress-life curve for the unfretted fatigue specimens was very flat. The flat appearance in the stress-life curve of the unfretted specimens is attributed to the presence of a high density of casting pores. The fatigue strengths of both the fretted and unfretted specimens can be significantly affected by the presence of this porosity, which can decrease the fatigue life of Ti-48Al-2Cr-2Nb. The presence of the porosity made discerning the effect of fretting damage on fatigue strength and life of the specimens difficult.

Miyoshi, Kazuhisa↗
DOE OSTI2019

Machining of Wrought Alloy 316L Specimens to Evaluate Elevated-Temperature Fatigue and Creep-Fatigue Properties

At the 2019 GAIN Microreactors workshop, a need to fabricate microreactor components through advanced manufacturing (AM) was conveyed by microreactor developers. Powder metallurgy (PM) hot isostatic pressing (HIP) is more mature than other AM techniques and thus more readily deployable in the near term. The elevated-temperature cyclic properties of materials manufactured by PM HIP, however, have not been established. Work is currently in progress to evaluate the elevated-temperature cyclic properties of Alloy 316L manufactured by PM HIP. These properties need to be compared to those of wrought Alloy 316L in order to understand the effect of PM HIP. Therefore, wrought Alloy 316L testing at the same conditions as those tested for the PM HIP is necessary. This statement of work provides instructions and requirements for the machining of wrought Alloy 316L specimens.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2004

Durability Assessment of Gamma Tial

Gamma TiAl was evaluated as a candidate alloy for low-pressure turbine blades in aeroengines. The durability of g-TiAl was studied by examining the effects of impact or fretting on its fatigue strength. Cast-to-size Ti-48Al-2Cr-2Nb was studied in impact testing with different size projectiles at various impact energies as the reference alloy and subsequently fatigue tested. Impacting degraded the residual fatigue life. However, under the ballistic impact conditions studied, it was concluded that the impacts expected in an aeroengine would not result in catastrophic damage, nor would the damage be severe enough to result in a fatigue failure under the anticipated design loads. In addition, other gamma alloys were investigated including another cast-to-size alloy, several cast and machined specimens, and a forged alloy. Within this Ti-48-2-2 family of alloys aluminum content was also varied. The cracking patterns as a result of impacting were documented and correlated with impact variables. The cracking type and severity was reasonably predicted using finite element models. Mean stress affects were also studied on impact-damaged fatigue samples. The fatigue strength was accurately predicted based on the flaw size using a threshold-based, fracture mechanics approach. To study the effects of wear due to potential applications in a blade-disk dovetail arrangement, the machined Ti-47-2-2 alloy was fretted against In-718 using pin-on-disk experiments. Wear mechanisms were documented and compared to those of Ti-6Al-4V. A few fatigue samples were also fretted and subsequently fatigue tested. It was found that under the conditions studied, the fretting was not severe enough to affect the fatigue strength of g-TiAl.

Draper, Susan L.↗
NASA NTRS1994

Application of Self Nulling Eddy Current Probe Technique to the Detection of Fatigue Crack Initiation and Control of Test Procedures

A major part of fracture mechanics is concerned with studying the initiation and propagation of fatigue cracks. This typically requires constant monitoring of crack growth during fatigue cycles and the knowledge of the precise location of the crack tip at any given time. One technique currently available for measuring fatigue crack length is the Potential Drop method. The method, however, may be inaccurate if the direction of crack growth deviates considerably from what was assumed initially or the curvature of the crack becomes significant. Another popular approach is to optically view the crack using a high magnification microscope, but this entails a person constantly monitoring it. The present proposed technique uses an automated scheme, in order to eliminate the need for a person to constantly monitor the experiment. Another technique under development elsewhere is to digitize an optical image of the test specimen surface and then apply a pattern recognition algorithm to locate the crack tip. A previous publication showed that the self nulling eddy current probe successfully tracked a simulated crack in an aluminum sample. This was the impetus to develop an online real time crack monitoring system. An automated system has been developed which includes a two axis scanner mounted on the tensile testing machine, the probe and its instrumentation and a personal computer (PC) to communicate and control all the parameters. The system software controls the testing parameters as well as monitoring the fatigue crack as it propagates. This paper will discuss the experimental setup in detail and demonstrate its capabilities. A three dimensional finite element model is utilized to model the magnetic field distribution due to the probe and how the probe voltage changes as it scans the crack. Experimental data of the probe for different samples under zero load, static load and high cycle fatigue load will be discussed. The final section summarizes the major accomplishments of the present work, the elements of the future R&D needs and the advantages and disadvantages of using this system in the laboratory and field.

Namkung, M.↗
NASA NTRS1987

Mechanisms of rolling contact spalling

The results of a study aimed at analyzing the mechanical material interactions responsible for rolling contact spalling of the 440 C steel, high pressure oxygen turbopump bearings are presented. A coupled temperature displacement finite element analysis of the effects of friction heating under the contact is presented. The contact is modelled as a stationary, heat generating, 2 dimensional indent in an elastic perfectly plastic half-space with heat fluxes up to 8.6 x 10000 KW/m sq comparable to those generated in the bearing. Local temperatures in excess of 1000 C are treated. The calculations reveal high levels of residual tension after the contact is unloaded and cools. Efforts to promote Mode 2/Mode 3 fatigue crack growth under cyclic torsion in hardened 440 C steel are described. Spalls produced on 440 C steel by a 3 ball/rod rolling contact testing machine were studied with scanning microscopy. The shapes of the cyclic, stress strain hysteresis loops displayed by hardened 440 C steel in cyclic torsion at room temperature are defined for the plastic strain amplitudes encountered in rolling/sliding contact. Results of these analyses are discussed in detail.

Kumar, A. M.↗
NASA NTRS1975

A life study of ausforged, standard forged, and standard machined AISI M-50 spur gears

Tests were conducted at 350 K with three groups of 8.9 cm pitch diameter spur gears made of vacuum-induction melted (VIM), vacuum-arc remelted (VAR), AISI M-50 steel and one group of vacuum-arc remelted (VAR) AISI 9310 steel. The pitting fatigue life of the standard forged and ausforged gears was approximately five times that of the VAR AISI 9310 gears and ten times that of the bending fatigue life of the standard machined VIM-VAR AISI M-50 gears run under identical conditions. There was a slight decrease in the 10-percent life of the ausforged gears from that for the standard forged gears. However, the difference is not statistically significant. The standard machined gears failed primarily by gear tooth fracture while the forged and ausforged VIM-VAR AISI M-50 and the VAR AISI 9310 gears failed primarily by surface pitting fatigue. The ausforged gears had a slightly greater tendency to fail by tooth fracture than the standard forged gears.

Townsend, D. P.↗
NASA NTRS2000

Fatigue, Creep-Fatigue, and Thermomechanical Fatigue Life Testing of Alloys

The fatigue crack initiation resistance of an alloy is determined by conducting a series of tests over a range of values of stress amplitude or strain range. The observed number of cycles to failure is plotted against the stress amplitude or strain range to obtain a fatigue curve. The fatigue properties quoted for an alloy are typically the constants used in the equation(s) that describe the fatigue curve. Fatigue lives of interest may be as low as 10(exp 2) or higher than 10(exp 9) cycles. Because of the enormous scatter associated with fatigue, dozens of tests may be needed to confidently establish a fatigue curve, and the cost may run into several thousands of dollars. To further establish the effects on fatigue life of the test temperature, environment, alloy condition, mean stress effects, creep-fatigue effects, thermomechanical cycling, etc. requires an extraordinarily large and usually very costly test matrix. The total effort required to establish the fatigue resistance of an alloy should not be taken lightly. Fatigue crack initiation tests are conducted on relatively small and presumed to be initially crack-free, samples of an alloy that are intended to be representative of the alloy's metallurgical and physical condition. Generally, samples are smooth and have uniformly polished surfaces within the test section. Some may have intentionally machined notches of well-controlled geometry, but the surface at the root of the notch is usually not polished. The purpose of polishing is to attain a reproducible surface finish. This is to eliminate surface finish as an uncontrolled variable. Representative test specimen geometries will be discussed later. Test specimens are cyclically loaded until macroscopically observable cracks initiate and eventually grow to failure. Normally, the fatigue failure life of a specimen is defined as the number of cycles to separation of the specimen into two pieces. Alternative definitions are becoming more common, particularly for low-cycle fatigue testing, wherein some prescribed indication of impending failure due to cracking is adopted. Specific criteria will be described later. As a rule, cracks that develop during testing are not measured nor are the test parameters intentionally altered owing to the presence of cracking.

Halford, Gary R.↗
DOE OSTI2026

A Data-Driven Method for Modeling Creep-Fatigue Stress- Strain Behavior Using Neural ODEs

In this paper, we introduce a data-driven machine learning approach for modeling one-dimensional stress–strain behavior under cyclic loading, utilizing experimental data from the nickel-based Alloy 617. The study employs uniaxial creep–fatigue test data acquired under various loading histories and compares two distinct neural network-based ODE models. The first model, known as the black-box model, comprehensively describes the strain–stress relationship using a Neural ODE equation. To interpret this black-box model, we apply the Sparse Identification of Nonlinear Dynamical Systems (SINDy) technique, transforming the black-box model into an equation-based model using symbolic regression. The second model, the Neural flow rule model, incorporates Hooke’s Law for the linear elastic component, with the nonlinear part characterized by a Neural ODE. Both models are trained with experimental data to accurately reflect the observed stress–strain behavior. We conduct a detailed comparison with the standard Chaboche model, which includes three back stresses. Our results demonstrate that the neural network-based ODE models precisely capture the experimental creep–fatigue mechanical behavior, exceeding the standard Chaboche model’s accuracy. Furthermore, an interpretable model derived from the black-box neural ODE model through symbolic regression achieves accuracy comparable to the Chaboche model, enhancing its interpretability. The results highlight the potential of neural network-based ODE models to depict complex creep–fatigue behavior, eliminating the necessity for experts to define a specific, material-focused model form.

creep-fatigue↗