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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

Space Shuttle Orbiter engine main combustion chamber cooling and life

A reusable life requirement of 100 missions is met by controlling the combustion chamber hot-gas wall temperature and strain levels. Maximum life, maximum performance, and minimum engine weight are attained through a descriptive parametric assessment of the regenerative cooling circuit, combustor length, contraction area ratio, and coolant passage geometry. Life is categorized by low-cycle fatigue and creep-stress rupture. Relationships are developed to determine the impact of heat transfer rate, thermal strain level, and geometric influence parameters on life. It is empirically shown that a throat heat flux of 100 Btu/sq in./sec can be accommodated.

Cook, R. T.↗
NASA NTRS1982

Hot isostatically pressed manufacture of high strength MERL 76 disk and seal shapes

The feasibility of using MERL 76, an advanced high strength direct hot isostatic pressed powder metallurgy superalloy, as a full scale component in a high technology, long life, commercial turbine engine were demonstrated. The component was a JT9D first stage turbine disk. The JT9D disk rim temperature capability was increased by at least 22 C and the weight of JT9D high pressure turbine rotating components was reduced by at least 35 pounds by replacement of forged Superwaspaloy components with hot isostatic pressed (HIP) MERL 76 components. The process control plan and acceptance criteria for manufacture of MERL 76 HIP consolidated components were generated. Disk components were manufactured for spin/burst rig test, experimental engine tests, and design data generation, which established lower design properties including tensile, stress-rupture, 0.2% creep and notched (Kt = 2.5) low cycle fatigue properties, Sonntag, fatigue crack propagation, and low cycle fatigue crack threshold data. Direct HIP MERL 76, when compared to conventionally forged Superwaspaloy, is demonstrated to be superior in mechanical properties, increased rim temperature capability, reduced component weight, and reduced material cost by at least 30% based on 1980 costs.

Eng, R. D.↗
NASA NTRS1991

System reliability and risk assessment task goals and status

The major focus for continued development of the Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) codes is in support of system testing and certification of advanced propulsion systems. Propulsion system testing has evolved over the years from tests designed to show success, to tests designed to reveal reliability issues before service use. Such test conditions as performance envelope corners, high rotor imbalance, power dwells, and overspeed tests are designed to shake out problems that can be associated with low and high cycle fatigue, creep, and stress rupture, bearing durability, and the like. Subsystem testing supports system certification by standing as an early evaluation of the same durability and reliability concerns as for the entire system. The NESSUS software system is being further developed to support the definition of rigorous subsystem and system test definition and reliability certification. The principal technical issues are outlined which are related to system reliability, including key technology issues such as failure mode synergism, sequential failure mechanisms, and fault tree definition.

Cruse, T. A.↗
NASA NTRS1993

A Modeling Investigation of Thermal and Strain Induced Recovery and Nonlinear Hardening in Potential Based Viscoplasticity

Specific forms for both the Gibb's and the complementary dissipation potentials were chosen such that a complete potential based multiaxial, isothermal, viscoplastic model was obtained. This model in general possesses three internal state variables (two scalars associated with dislocation density and one tensor associated with dislocation motion) both thermal and dynamic recovery mechanisms, and nonlinear kinematic hardening. This general model, although possessing associated flow and evolutionary laws, is shown to emulate three distinct classes of theories found in the literature, by modification of the driving threshold function F. A parametric study was performed on a specialized nondimensional multiaxial form containing only a single tensorial internal state variable (i.e., internal stress). The study was conducted with the idea of examining the impact of including a strain-induced recovery mechanism and the compliance operator, derived from the Gibb's potential, on the uniaxial and multiaxial response. One important finding was that inclusion of strain recovery provided the needed flexibility in modeling stress-strain and creep response of metals at low homologous temperatures, without adversely affecting the high temperature response. Furthermore, for nonproportional loading paths, the inclusion of the compliance operator had a significant influence on the multiaxial response, but had no influence on either uniaxial or proportional load histories.

Arnold, S. M.↗
NASA NTRS1993

Inelastic deformation of metal matrix composites

A theoretical model capable of predicting the thermomechanical response of continuously reinforced metal matrix composite laminates subjected to multiaxial loading was developed. A micromechanical model is used in conjunction with nonlinear lamination theory to determine inelastic laminae response. Matrix viscoplasticity, residual stresses, and damage to the fiber/matrix interfacial zone are explicitly included in the model. The representative cell of the micromechanical model is considered to be in a state of generalized plane strain, enabling a quasi two-dimensional analysis to be performed. Constant strain finite elements are formulated with elastic-viscoplastic constitutive equations. Interfacial debonding is incorporated into the model through interface elements based on the interfacial debonding theory originally presented by Needleman, and modified by Tvergaard. Nonlinear interfacial constitutive equations relate interfacial tractions to displacement discontinuities at the interface. Theoretical predictions are compared with the results of an experimental program conducted on silicon carbide/titanium (SiC/Ti) unidirectional, (O4), and angle-ply, (+34)(sub s), tubular specimens. Multiaxial loading included increments of axial tension, compression, torque, and internal pressure. Loadings were chosen in an effort to distinguish inelastic deformation due to damage from matrix plasticity and separate time-dependent effects from time-independent effects. Results show that fiber/matrix debonding is nonuniform throughout the composite and is a major factor in the effective response. Also, significant creep behavior occurs at relatively low applied stress levels at room temperature.

Lissenden, C. J.↗
NASA NTRS1997

The International Space Station Assembly on Schedule

As engineers continue to prepare the International Space Station (ISS) for in-orbit assembly in the year 2002, ANSYS software has proven instrumental in resolving a structural problem in the project's two primary station modules -- Nodes 1 and 2. Proof pressure tests performed in May revealed "low temperature, post-yield creep" in some of the Nodes' gussets, which were designed to reinforce ports for loads from station keeping and reboost motion of the entire space station. An extensive effort was undertaken to characterize the creep behavior of the 2219-T851 aluminum forging material from which the gussets were made. Engineers at Sverdrup Technology, Inc. (Huntsville, AL) were responsible for conducting a combined elastic-plastic-creep analysis of the gussets to determine the amount of residual compressive stress which existed in the gussets following the proof pressure tests, and to determine the stress-strain history in the gussets while on-orbit. Boeing, NASA's Space Station prime contractor, supplied the Finite Element Analysis (FEA) model geometry and developed the creep equations from the experimental data taken by NASA's Marshall Space Flight Center and Langley Research Center. The goal of this effort was to implement the uniaxial creep equations into a three dimensional finite element program, and to determine analytically whether or not the creep was something that the space station program could live with. The objective was to show analytically that either the creep rate was at an acceptable level, or that the node module had to be modified to lower the stress levels to where creep did not occur. The elastic-plastic-creep analysis was performed using the ANSYS finite element program of ANSYS, Inc. (Houston, PA). The analysis revealed that the gussets encountered a compressive stress of approximately 30,000 pounds per square inch (psi) when unloaded. This compressive residual stress significantly lowered the maximum tension stress in the gussets which decreased the creep strain rate. The analysis also showed that the gussets would not experience a great deal of creep from future pressure tests if braces or struts proposed by Boeing were installed to redistribute stress away from them. Subsequent analysis of on-orbit station keeping and reboost loads convinced Boeing that the gussets should be removed altogether.

Source record↗
NASA NTRS2005

Full-Scale GRCop-84 Combustion Chamber Liner Preform Fabricated Successfully

GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) has been under development at the NASA Glenn Research Center for several years. The alloy possesses a unique combination of good thermal conductivity, high elevated temperature strength, long creep life, and long low-cycle- fatigue. The alloy is also more oxidation resistant than pure copper and most competitive alloys. The combination of properties has attracted attention from major rocket engine manufacturers who are interested in the alloy for the combustion chamber liner in their next generation of regeneratively cooled engines. Before GRCop-84 can be used in a main combustion chamber application, it must be demonstrated that the alloy can be made successfully to the large sizes and proper shape needed and that it retain useful properties. Recent efforts have successfully demonstrated the ability to fabricate a liner preform via metal spinning that retains the alloy s strength even in the welded sections.

Ellis, David L.↗
NASA NTRS2005

Fabrication of GRCop-84 Rocket Thrust Chambers

GRCop-84, a copper alloy, Cu-8 at% Cr-4 at% Nb developed at NASA Glenn Research Center for regeneratively cooled rocket engine liners has excellent combinations of elevated temperature strength, creep resistance, thermal conductivity and low cycle fatigue. GRCop-84 is produced from prealloyed atomized powder and has been fabricated into plate, sheet and tube forms as well as near net shapes. Fabrication processes to produce demonstration rocket combustion chambers will be presented and includes powder production, extruding, rolling, forming, friction stir welding, and metal spinning. GRCop-84 has excellent workability and can be readily fabricated into complex components using conventional powder and wrought metallurgy processes. Rolling was examined in detail for process sensitivity at various levels of total reduction, rolling speed and rolling temperature representing extremes of commercial processing conditions. Results indicate that process conditions can range over reasonable levels without any negative impact to properties.

Loewenthal, William S.↗
NASA NTRS2006

Fabrication of GRCop-84 Rocket Thrust Chambers

GRCop-84, a copper alloy, Cu-8 at% Cr-4 at% Nb developed at NASA Glenn Research Center for regenerative1y cooled rocket engine liners has excellent combinations of elevated temperature strength, creep resistance, thermal conductivity and low cycle fatigue. GRCop-84 is produced from pre-alloyed atomized powder and has been fabricated into plate, sheet and tube forms as well as near net shapes. Fabrication processes to produce demonstration rocket combustion chambers will be presented and includes powder production, extruding, rolling, forming, friction stir welding, and metal spinning. GRCop-84 has excellent workability and can be readily fabricated into complex components using conventional powder and wrought metallurgy processes. Rolling was examined in detail for process sensitivity at various levels of total reduction, rolling speed and rolling temperature representing extremes of commercial processing conditions. Results indicate that process conditions can range over reasonable levels without any negative impact to properties.

Loewenthal, William↗
NASA NTRS2006

Predicting Lifetime of a Thermomechanically Loaded Component

NASALIFE is a computer program for predicting the lifetime, as affected by low cycle fatigue (LCF) and creep rupture, of a structural component subject to temporally varying, multiaxial thermomechanical loads. The component could be, for example, part of an aircraft turbine engine. Empirical data from LCF tests, creep rupture tests, and static tensile tests are used as references for predicting the number of missions the component can withstand under a given thermomechanical loading condition. The user prepares an input file containing the creep-rupture and cyclic-fatigue information, temperature-dependent material properties, and mission loading and control flags. The creep rupture information can be entered in tabular form as stress versus life or by means of parameters of the Larson-Miller equation. The program uses the Walker mean-stress model to adjust predicted life for ranges of the ratio between the maximum and minimum stresses. Data representing complex load cycles are reduced by the rainflow counting method. Miner's rule is utilized to combine the damage at different load levels. Finally, the program determines the total damage due to creep and combines it with the fatigue damage due to the cyclic loading and predicts the approximate number of missions a component can endure before failing.

Murthy, Pappu L. N.↗
NASA NTRS2011

Monolithic Flexure Pre-Stressed Ultrasonic Horns

High-power ultrasonic actuators are generally assembled with a horn, backing, stress bolt, piezoelectric rings, and electrodes. The manufacturing process is complex, expensive, difficult, and time-consuming. The internal stress bolt needs to be insulated and presents a potential internal discharge point, which can decrease actuator life. Also, the introduction of a center hole for the bolt causes many failures, reducing the throughput of the manufactured actuators. A new design has been developed for producing ultrasonic horn actuators. This design consists of using flexures rather than stress bolts, allowing one to apply pre-load to the piezoelectric material. It also allows one to manufacture them from a single material/plate, rapid prototype them, or make an array in a plate or 3D structure. The actuator is easily assembled, and application of pre-stress greater than 25 MPa was demonstrated. The horn consists of external flexures that eliminate the need for the conventional stress bolt internal to the piezoelectric, and reduces the related complexity. The stress bolts are required in existing horns to provide prestress on piezoelectric stacks when driven at high power levels. In addition, the manufacturing process benefits from the amenability to produce horn structures with internal cavities. The removal of the pre-stress bolt removes a potential internal electric discharge point in the actuator. In addition, it significantly reduces the chances of mechanical failure in the piezoelectric stacks that result from the hole surface in conventional piezoelectric actuators. The novel features of this disclosure are: 1. A design that can be manufactured from a single piece of metal using EDM, precision machining, or rapid prototyping. 2. Increased electromechanical coupling of the horn actuator. 3. Higher energy density. 4. A monolithic structure of a horn that consists of an external flexure or flexures that can be used to pre-stress a solid piezoelectric structure rather than a bolt, which requires a through hole in the piezoelectric material. 5. A flexure system with low stiffness that accommodates mechanical creep with minor reduction in pre-stress.

Sherrit, Stewart↗
NASA NTRS1995

A new Cu-8 Cr-4 Nb alloy for high temperature applications

Various applications exist where a high conductivity alloy with good strength and creep resistance are required. NASA LeRC has developed a Cu-8 at. percent Cr-4 at. percent Nb (Cu-8 Cr-4 Nb) alloy for these applications. The alloy is designed for use up to 700 C and shows exceptional strength, low cycle fatigue (LCF) resistance, and creep resistance. Cu-8 Cr-4 Nb also has a thermal conductivity of at least 72 percent that of pure Cu. Furthermore, the microstructure and mechanical properties of the alloy are very stable. In addition to the original application in combustion chambers, Cu-8 Cr-4 Nb shows promise for welding electrodes, brazing fixtures, and other applications requiring high conductivity and strength at elevated temperatures.

Ellis, D. L.↗
NASA NTRS1980

Creep-rupture behavior of seven iron-base alloys after long term aging at 760 deg in low pressure hydrogen

Seven candidate iron-base alloys for heater tube application in the Stirling automotive engine were aged for 3500 hours at 760 C in argon and hydrogen. Aging degraded the tensile and creep-rupture properties. The presence of hydrogen during aging caused additional degradiation of the rupture strength in fine grain alloys. Based on current design criteria for the Mod 1 Stirling engine, N-155 and 19-9DL are considered the only alloys in this study with strengths adequate for heater tube service at 760 C.

Witzke, W. R.↗
NASA NTRS1982

Creep and rupture of an ODS alloy with high stress rupture ductility

The creep and stress rupture properties of an oxide (Y2O3) dispersion strengthened nickel-base alloy, which also is strengthened by gamma-prime precipitates, was studied at 760 and 1093 C. At both temperatures, the alloy YDNiCrAl exhibits unusually high stress rupture ductility as measured by both elongation and reduction in area. Failure was transgranular, and different modes of failure were observed including crystallographic fracture at intermediate temperatures and tearing or necking almost to a chisel point at higher temperatures. While the rupture ductility was high, the creep strength of the alloy was low relative to conventional gamma prime strengthened superalloys in the intermediate temperature range and to ODS alloys in the higher temperature range. These findings are discussed with respect to the alloy composition; the strengthening oxide phases, which are inhomogeneously dispersed; the grain morphology, which is coarse and elongated and exhibits many included grains; and the second phase inclusion particles occurring at grain boundaries and in the matrix. The creep properties, in particular the high stress dependencies and high creep activation energies measured, are discussed with respect to the resisting stress model of creep in particle strengthened alloys.

Mcalarney, M. E.↗
NASA NTRS1996

Mechanical and Thermal Properties of Two Cu-Cr-Nb Alloys and NARloy-Z

A series of creep tests were conducted on Cu-8 Cr-4 Nb (Cu-8 at.% Cr-4 at.% Nb), Cu-4 Cr-2 Nb (Cu-4 at.% Cr-2 at% Nb), and NARloy-Z (Cu-3 wt.% Ag-0.5 wt.% Zr) samples to determine their creep properties. In addition, a limited number of low cycle fatigue and thermal conductivity tests were conducted. The Cu-Cr-Nb alloys showed a clear advantage in creep life and sustainable load over the currently used NARloy-Z. Increases in life at a given stress were between 100% and 250% greater for the Cu-Cr-Nb alloys depending on the stress and temperature. For a given life, the Cu-Cr-Nb alloys could support a stress between 60% and 160% greater than NARloy-Z. Low cycle fatigue lives of the Cu-8 Cr-4 Nb alloy were equivalent to NARloy-Z at room temperature. At elevated temperatures (538 C and 650 C), the fatigue lives were 50% to 200% longer than NARloy-Z samples tested at 538 C. The thermal conductivities of the Cu-Cr-Nb alloys remained high, but were lower than NARloy-Z and pure Cu. The Cu-Cr-Nb thermal conductivities were between 72% and 96% that of pure Cu with the Cu-4 Cr-2 Nb alloy having a significant advantage in thermal conductivity over Cu-8 Cr4 Nb. In comparison, stainless steels with equivalent strengths would have thermal conductivities less than 25% the thermal conductivity of pure Cu. The combined results indicate that the Cu-Cr-Nb alloys offer an attractive alternative to current high temperature Cu-based alloys such as NARloy-Z.

Ellis, David L.↗
NASA NTRS2000

The Combined Influence of Molecular Weight and Temperature on the Aging and Viscoelastic Response of a Glassy Thermoplastic Polyimide

The effect of molecular weight on the viscoelastic performance of an advanced polymer (LaRC-SI) was investigated through the use of creep compliance tests. Testing consisted of short-term isothermal creep and recovery with the creep segments performed under constant load. The tests were conducted at three temperatures below the glass transition temperature of five materials of different molecular weight. Through the use of time-aging-time superposition procedures, the material constants, material master curves and aging-related parameters were evaluated at each temperature for a given molecular weight. The time-temperature superposition technique helped to describe the effect of temperature on the timescale of the viscoelastic response of each molecular weight. It was shown that the low molecular weight materials have higher creep compliance and creep rate, and are more sensitive to temperature than the high molecular weight materials. Furthermore, a critical molecular weight transition was observed to occur at a weight-average molecular weight of M (bar) (sub w) 25000 g/mol below which, the temperature sensitivity of the time-temperature superposition shift factor increases rapidly. The short-term creep compliance data were used in association with Struik's effective time theory to predict the long-term creep compliance behavior for the different molecular weights. At long timescales, physical aging serves to significantly decrease the creep compliance and creep rate of all the materials tested.

Nicholson, Lee M.↗
NASA NTRS2000

Molecular Weight Effects on the Viscoelastic Response of a Polyimide

The effect of molecular weight on the viscoelastic performance of an advanced polymer (LaRC -SI) was investigated through the use of creep compliance tests. Testing consisted of short-term isothermal creep and recovery with the creep segments performed under constant load. The tests were conducted at three temperatures below the glass transition temperature of each material with different molecular weight. Through the use of time-aging-time superposition procedures, the material constants, material master curves and aging-related parameters were evaluated at each temperature for a given molecular weight. The time-temperature superposition technique helped to describe the effect of temperature on the timescale of the viscoelastic response of each molecular weight. It was shown that the low molecular weight materials have increased creep compliance and creep compliance rate, and are more sensitive to temperature than the high molecular weight materials. Furthermore, a critical molecular weight transition was observed to occur at a weight-average molecular weight of approximately 25000 g/mol below which, the temperature sensitivity of the time-temperature superposition shift factor increases rapidly.

Nicholson, Lee M.↗
NASA NTRS2003

Microstructure and Mechanical Properties of Extruded Gamma Met PX

A gamma TiAl alloy with a high Nb content is being assessed as a compressor blade material. The microstructure and mechanical properties of extruded Ti-45Al-X(Nb,B,C) (at %) were evaluated in both an as-extruded condition and after a lamellar heat treatment. Tensile behavior of both as-extruded and lamellar heat treated specimens was studied in the temperature range of RT to 926 C. In general, the yield stress and ultimate tensile strength reached relatively high values at room temperature and decreased with increasing deformation temperature. The fatigue strength of both microstructures was characterized at 650 C and compared to a baseline TiAl alloy and to a Ni-base superalloy. Tensile and fatigue specimens were also exposed to 800 C for 200 h in air to evaluate the alloy's environmental resistance. A decrease in ductility was observed at room temperature due to the 800 C exposure but the 650 C fatigue properties were unaffected. Compressive and tensile creep testing between 727 and 1027 C revealed that the creep deformation was reproducible and predictable. Creep strengths reached superalloy-like levels at fast strain rates and lower temperatures but deformation at slower strain rates and/or higher temperature indicated significant weakening for the as-extruded condition. At high temperatures and low stresses, the lamellar microstructure had improved creep properties when compared to the as-extruded material. Microstructural evolution during heat treatment, identification of various phases, and the effect of microstructure on the tensile, fatigue, and creep behaviors is discussed.

Draper, S. L.↗