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NASA NTRS2001

Longtime Durability of PMR-15 Matrix Polymer at 204, 260, 288, and 316 C

Isothermal weight loss studies at the Glenn (Lewis) Research Center were conducted at four temperatures (204, 260, 288, and 316 C) with specimens of varied geometric shapes to investigate the mechanisms involved in the thermal degradation of PMR-15. Both neat resin behavior and composite behaviors were studied. Two points of interest in these studies are the role(s) of oxygen in the mechanisms involved in the thermo-oxidative degradation of these composite materials and the dimensional changes that occur during their useable lifetime. Specimen dimensional changes and surface layer growth were measured and recorded. It was shown that physical and chemical changes take place as a function of time and location in PMR-15 neat resin and composites as aging takes place in air at elevated temperatures. These changes initiate at the outer surfaces of both materials and progress inward following the oxygen as it proceeds by diffusion into the central core of each material. Microstructural changes cause changes in density, material shrinkage (strains), glass transition temperature, dimension, dynamic shear modulus, and compression properties. These changes also occur slowly dividing the polymer material into two distinct parts: a visibly undamaged core section between two visibly damaged surface layers. The surface layer has a significant effect on compression properties of thinner specimens, but the visibly undamaged core material controls these properties for specimens having eight or more plies. It was demonstrated that there are three different mechanisms involved in the degradation of PMR-15 during aging at elevated temperatures. These are a weight gain, a small weight fraction bulk material weight loss, and a large mass fraction weight loss concentrated at the surface of the polymer or composite. At the higher temperatures (260 C and above), the surface loss predominates. Below 260 C, the surface loss and the bulk core loss become more equivalent. Between 175 and 260 C, the initial weight change is due to a weight gain mechanism with a visible lifetime that diminishes as the aging temperature increases.

Bowles, Kenneth J.↗

NASA NTRS1998

Void Management in MEPHISTO and Other Space Experiments

The second flight of NASA's Shuttle Flight experiment program known as MEPHISTO suffered from a void in the liquid portion of the sample, even though a piston arrangement was in place to keep the ampoule filled. In preparations for the next flight of the MEPHISTO furnace an animated computer program, called MEPHISTO Volume Visualizer (MVV), was written to help avoid the formation of unwanted voids. A piston system on MEPHISTO has the ability to move approximately 5 mm in compression, to accommodate expansion of the solid during heating; then from the completely compressed position, the piston can move up to 25 mm in towards the sample, effectively making the ampoule smaller and hopefully eliminating any voids. Due to the nature of the piston design and ampoule and sample arrangement, the piston has gotten stuck during normal directional solidification; this creates the risk of a void. To eliminate such a void, the liquid in the hot zones of the furnace can be heated, thereby expanding the liquid and consuming any void. The problem with this approach is that if the liquid is heated too much an overpressure could result, breaking the ampoule and ending the experiment catastrophically. The MVV has been found to be a useful tool in the assessment of the risks associated with the formation of a void and the additional heating of the liquid in the hot zone of this Bridgman type furnace. The MVV software will be discussed and copies available; it is written in the Delphi 2 programming language and runs under Windows 95 and NT. The strategies used in other flight experiments, such as the Isothermal Dendritic Growth Experiment, will also be presented.

deGroh, Henry C., III↗

NASA NTRS1989

Procedures for characterizing an alloy and predicting cyclic life with the total strain version of Strainrange Partitioning

Procedures are presented for characterizing an alloy and predicting cyclic life for isothermal and thermomechanical fatigue conditions by using the total strain version of strainrange partitioning (TS-SRP). Numerical examples are given. Two independent alloy characteristics are deemed important: failure behavior, as reflected by the inelastic strainrange versus cyclic life relations; and flow behavior, as indicated by the cyclic stress-strain-time response (i.e., the constitutive behavior). Failure behavior is characterized by conducting creep-fatigue tests in the strain regime, wherein the testing times are reasonably short and the inelastic strains are large enough to be determined accurately. At large strainranges, stress-hold, strain-limited tests are preferred because a high rate of creep damage per cycle is inherent in this type of test. At small strainranges, strain-hold cycles are more appropriate. Flow behavior is characterized by conducting tests wherein the specimen is usually cycled far short of failure and the wave shape is appropriate for the duty cycle of interest. In characterizing an alloy pure fatigue, or PP, failure tests are conducted first. Then depending on the needs of the analyst a series of creep-fatigue tests are conducted. As many of the three generic SRP cycles are featured as are required to characterize the influence of creep on fatigue life (i.e., CP, PC, and CC cycles, respectively, for tensile creep only, compressive creep only, and both tensile and compressive creep). Any mean stress effects on life also must be determined and accounted for when determining the SRP inelastic strainrange versus life relations for cycles featuring creep. This is particularly true for small strainranges. The life relations thus are established for a theoretical zero mean stress condition.

Saltsman, James F.↗

NASA NTRS2012

The Evolution of Friction Stir Welding Theory at Marshall Space Flight Center

From 1995 to the present the friction stir welding (FSW) process has been under study at Marshall Space Flight Center (MSFC). This is an account of the progressive emergence of a set of conceptual tools beginning with the discovery of the shear surface, wiping metal transfer, and the invention of a kinematic model and making possible a treatment of both metallurgical structure formation and process dynamics in friction stir welding from a unified point of view. It is generally observed that the bulk of the deformation of weld metal around the FSW pin takes place in a very narrow, almost discontinuous zone with high deformation rates characteristic of metal cutting. By 1999 it was realized that this zone could be treated as a shear surface like that in simple metal cutting models. At the shear surface the seam is drawn out and compressed and pressure and flow conditions determine whether or not a sound weld is produced. The discovery of the shear surface was followed by the synthesis of a simple 3- flow kinematic model of the FSW process. Relative to the tool the flow components are: (1) an approaching translational flow at weld speed V, (2) a rotating cylindrical plug flow with the angular velocity of the tool , and (3) a relatively slow ring vortex flow (like a smoke ring) encircling the tool and driven by shoulder scrolls and pin threads. The rotating plug flow picks up an element of weld metal, rotates it around with the tool, and deposits it behind the tool ( wiping metal transfer ); it forms plan section loops in tracers cut through by the tool. Radially inward flow from the ring vortex component retains metal longer in the rotating plug and outward flow expels metal earlier; this interaction forms the looping weld seam trace and the tongue and groove bimetallic weld contour. The radial components of the translational and ring vortex flows introduce parent metal intrusions into the small grained nugget material close to the tool shoulder; if this feature is pronounced, nugget collapse may result. Certain weld features, in particular internal banding seen in transverse section as onion rings and associated surface ridges called tool marks , have long implied an oscillation flow component, but have only recently been attributed in the literature to tool eccentricity. Rotating plug shape, typically a hollow cylinder flared at the end where it sticks to the shoulder, varies as pressure distribution on the tool determines where sticking occurs. Simplified power input estimates balanced against heat loss estimates give reasonable temperature estimates, explain why the power requirement changes hardly at all over a wide range of RPM s, and yield isotherms that seem to fall along boundaries of parameter windows of operation.

Nunes, Arthur C.↗