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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Creep-rupture behavior of 6 candidate stirling engine iron-base superalloys in high pressure hydrogen. Volume 1: Air creep-rupture behavior

Four wrought alloys (A-286, IN 800H, N-155, and 19-9DL) and two cast alloys (CRM-6D and XF-818) were tested to determine their creep-rupture behavior. The wrought alloys were used in the form of sheets of 0.89 mm (0.035 in.) average thickness. The cast alloy specimens were investment cast and machined to 6.35 mm (0.250 in.) gage diameter. All specimens were tested to rupture in air at different times up to 3000 h over the temperature range of 650 C to 925 C (1200 F to 1700 F). Rupture life, minimum creep rate, and time to 1% creep strain were statistically analyzed as a function of stress at different temperatures. Temperature-compensated analysis was also performed to obtain the activation energies for rupture life, time to 1% creep strain, and the minimum creep rate. Microstructural and fracture analyses were also performed. Based on statistical analyses, estimates were made for stress levels at different temperatures to obtain 3500 h rupture life and time to 1% creep strain. Test results are to be compared with similar data being obtained for these alloys under 15 MPa (2175 psi) hydrogen.

Bhattacharyya, S.↗
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 NTRS1995

Geologic investigations of a 'slip gap' in the surficial ruptures of the 1992 Landers earthquake, southern California

A 3-km-long gap in the dextral surficial rupture of the 1992 M(sub W) = 7.3 Landers earthquake occurs at the north end of a major fault stepover between the Johnson Valley and Homestead Valley faults. This gap is situated along a segment of the Landers rupture that has been modeled geophysically as having a deficit in average slip at depth. To better evaluate the nature of the slip gap, we document in detail the character and distribution of surficial rupture within it. Along the gap, is a northwest trending thrust fault rupture with an average of less than 1 m of northeast directed reverse-slip and nearly no oblique right slip. We interpret this rupture to be limited to the shallow crust of the northern end of the stepover and to have been the secondary result of dextral shear, rather than a mechanism of rigid-block slip-transfer from the Landers-Kickapoo fault. A zone of en echelon extensional ruptures also occurs along the slip gap, which we interpret as the secondary result of diffuse dextral shear that accommodated less than 0.5 m of west-northwest extension. These secondary ruptures represent a discontinuity in the surficial dextral ruptre of the Landers earthquake, which we propose resulted from the lack of a mature fault connection between the Johnson Valley and Homestead Valley faults. The rupture pattern of the slip gap implies a significant deficit in net surficial slip, which compares favorably with some geophysical models. Aspects of this rupture pattern also suggest a temporal sequence of rupture that compares favorably with geophysical interpretations of the dynamic rupture propagation.

Spotila, James A.↗
NASA NTRS1972

Cyclic creep-rupture behavior of three high-temperature alloys.

Study of some important characteristics of the cyclic creep-rupture curves for the titanium alloy 6Al-2Sn-4Zr-2Mo at 900 and 1100 F (755 and 865 K), the cobalt-base alloy L-605 at 1180 F (910 K), and for two hardness levels of 316 stainless steel at 1300 F (980 K). The cyclic creep-rupture curve relates tensile stress and tensile time-to-rupture for strain-limited cyclic loading and has been found to be independent of the total strain range and the level of compressive stress employed in the cyclic creep-rupture tests. The cyclic creep-rupture curve was always found to be above and to the right of the conventional (constant load) monotonic creep-rupture curve by factors ranging from 2 to 10 in time-to-rupture. This factor tends to be greatest when the creep ductility is large. Cyclic creep acceleration was observed in every cyclic creep-rupture test conducted. The phenomenon was most pronounced at the highest stress levels and when the tensile and compressive stresses were completely reversed. In general, creep rates were found to be lower in compression than in tension for equal true stresses. The differences, however, were strongly material-dependent.

Halford, G. R.↗
NASA NTRS2000

Intermediate Temperature Stress Rupture of Woven SiC Fiber, BN Interphase, SiC Matrix Composites in Air

Tensile stress-rupture experiments were performed on woven Hi-Nicalon reinforced SiC matrix composites with BN interphases in air. Modal acoustic emission (AE) was used to monitor the damage accumulation in the composites during the tests and microstructural analysis was performed to determine the amount of matrix cracking that occurred for each sample. Fiber fractograph), was also performed for individual fiber failures at the specimen fracture surface to determine the strengths at which fibers failed. The rupture strengths were significantly worse than what would have been expected front the inherent degradation of the fibers themselves when subjected to similar rupture conditions. At higher applied stresses the rate of rupture "?as larger than at lower applied stresses. It was observed that the change in rupture rate corresponded to the onset of through-thickness cracking in the composites themselves. The primary cause of the sen,ere degradation was the ease with which fibers would bond to one another at their closest separation distances, less than 100 nanometers, when exposed to the environment. The near fiber-to-fiber contact in the woven tows enabled premature fiber failure over large areas of matrix cracks due to the stress-concentrations created b), fibers bonded to one another after one or a few fibers fail. i.e. the loss of global load sharing. An@, improvement in fiber-to-fiber separation of this composite system should result in improved stress- rupture properties. A model was den,eloped in order to predict the rupture life-time for these composites based on the probabilistic nature of indin,idual fiber failure at temperature. the matrix cracking state during the rupture test, and the rate of oxidation into a matrix crack. Also incorporated into the model were estimates of the stress-concentration that would occur between the outer rim of fibers in a load-bearing bundle and the unbridged region of a matrix crack after Xia et al. For the lower stresses, this source of stress-concentration was the likely cause for initial fiber failure that would trigger catastrophic failure of the composite.

Morscher, Gregory N.↗
NASA NTRS2011

Self-Rupturing Hermetic Valve

For commercial, military, and aerospace applications, low-cost, small, reliable, and lightweight gas and liquid hermetically sealed valves with post initiation on/off capability are highly desirable for pressurized systems. Applications include remote fire suppression, single-use system-pressurization systems, spacecraft propellant systems, and in situ instruments. Current pyrotechnic- activated rupture disk hermetic valves were designed for physically larger systems and are heavy and integrate poorly with portable equipment, aircraft, and small spacecraft and instrument systems. Additionally, current pyrotechnically activated systems impart high g-force shock loads to surrounding components and structures, which increase the risk of damage and can require additional mitigation. The disclosed mechanism addresses the need for producing a hermetically sealed micro-isolation valve for low and high pressure for commercial, aerospace, and spacecraft applications. High-precision electrical discharge machining (EDM) parts allow for the machining of mated parts with gaps less than a thousandth of an inch. These high-precision parts are used to support against pressure and extrusion, a thin hermetically welded diaphragm. This diaphragm ruptures from a pressure differential when the support is removed and/or when the plunger is forced against the diaphragm. With the addition of conventional seals to the plunger and a two-way actuator, a derivative of this design would allow nonhermetic use as an on/off or metering valve after the initial rupturing of the hermetic sealing disk. In addition, in a single-use hermetically sealed isolation valve, the valve can be activated without the use of potential leak-inducing valve body penetrations. One implementation of this technology is a high-pressure, high-flow-rate rupture valve that is self-rupturing, which is advantageous for high-pressure applications such as gas isolation valves. Once initiated, this technology is self-energizing and requires low force compared to current pyrotechnic-based burst disk hermetic valves. This is a novel design for producing a single-use, self-rupturing, hermetically sealed valve for isolation of pressurized gas and/or liquids. This design can also be applied for single-use disposable valves for chemical instruments. A welded foil diaphragm is fully supported by two mated surfaces that are machined to micron accuracies using EDM. To open the valve, one of the surfaces is moved relative to the other to (a) remove the support creating an unsupported diaphragm that ruptures due to over pressure, and/or (b) produce tension in the diaphragm and rupture it.

Tucker, Curtis E., Jr.↗
NASA NTRS1999

Intermediate Temperature Stress Rupture of a Woven Hi-Nicalon, BN-Interphase, SiC Matric Composite in Air

Woven Hi-Nicalon (TM) reinforced melt-infiltrated SiC matrix composites were tested under tensile stress-rupture conditions in air at intermediate temperatures. A comprehensive examination of the damage state and the fiber properties at failure was performed. Modal acoustic emission analysis was used to monitor damage during the experiment. Extensive microscopy of the composite fracture surfaces and the individual fiber fracture surfaces was used to determine the mechanisms leading to ultimate failure. The rupture properties of these composites were significantly worse than expected compared to the fiber properties under similar conditions. This was due to the oxidation of the BN interphase. Oxidation occurred through the matrix cracks that intersected the surface or edge of a tensile bar. These oxidation reactions resulted in minor degradation to fiber strength and strong bonding of the fibers to one another at regions of near fiber-to-fiber contact. It was found that two regimes for rupture exist for this material: a high stress regime where rupture occurs at a fast rate and a low stress regime where rupture occurs at a slower rate. For the high stress regime, the matrix damage state consisted of through thickness cracks. The average fracture strength of fibers that were pulled-out (the final fibers to break before ultimate failure) was controlled by the slow-crack growth rupture criterion in the literature for individual Hi-Nicalon (TM) fibers. For the low stress regime, the matrix damage state consisted of microcracks which grew during the rupture test. The average fracture strength of fibers that were pulled-out in this regime was the same as the average fracture strength of individual fibers pulled out in as-produced composites tested at room temperature.

Morscher, Gregory N.↗
NASA NTRS1999

Factors Controlling Stress Rupture of Fiber-Reinforced Ceramic Composites

The successful application of fiber-reinforced ceramic matrix composites (CMC) depends strongly on maximizing material rupture life over a wide range of temperatures and applied stresses. The objective of this paper is to examine the various intrinsic and extrinsic factors that control the high-temperature stress rupture of CMC for stresses below and above those required for cracking of the 0 C plies (Regions I and II, respectively). Using creep-rupture results for a variety of ceramic fibers and rupture data for CMC reinforced by these fibers, it is shown that in those cases where the matrix carries little structural load, CMC rupture conditions can be predicted very well from the fiber behavior measured under the appropriate test environment. As such, one can then examine the intrinsic characteristics of the fibers in order to develop design guidelines for selecting fibers and fiber microstructures in order to maximize CMC rupture life. For those cases where the fiber interfacial coatings are unstable in the test environment, CMC lives are generally worse than those predicted by fiber behavior alone. For those cases where the matrix can support structural load, CMC life can even be greater provided matrix creep behavior is properly controlled. Thus the achievement of long CMC rupture life requires understanding and optimizing the behavior of all constituents in the proper manner.

DiCarlo, J. A.↗
NASA NTRS2007

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifing Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle's Kevlar-49 fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed non-conservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic-plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23% lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗
NASA NTRS2009

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifting Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle s Kevlar-49 (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed nonconservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23 percent lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗
NASA NTRS2014

The Inclusion of Arbitrary Load Histories in the Strength Decay Model for Stress Rupture

Stress rupture is a failure mechanism where failures can occur after a period of time, even though the material has seen no increase in load. Carbon/epoxy composite materials have demonstrated the stress rupture failure mechanism. In a previous work, a model was proposed for stress rupture of composite overwrap pressure vessels (COPVs) and similar composite structures based on strength degradation. However, the original model was limited to constant load periods (holds) at constant load. The model was expanded in this paper to address arbitrary loading histories and specifically the inclusions of ramp loadings up to holds and back down. The broadening of the model allows for failures on loading to be treated as any other failure that may occur during testing instead of having to be treated as a special case. The inclusion of ramps can also influence the length of the "safe period" following proof loading that was previously predicted by the model. No stress rupture failures are predicted in a safe period because time is required for strength to decay from above the proof level to the lower level of loading. Although the model can predict failures during the ramp periods, no closed-form solution for the failure times could be derived. Therefore, two suggested solution techniques were proposed. Finally, the model was used to design an experiment that could detect the difference between the strength decay model and a commonly used model for stress rupture. Although these types of models are necessary to help guide experiments for stress rupture, only experimental evidence will determine how well the model may predict actual material response. If the model can be shown to be accurate, current proof loading requirements may result in predicted safe periods as long as 10(13) years. COPVs design requirements for stress rupture may then be relaxed, allowing more efficient designs, while still maintaining an acceptable level of safety.

Reeder, James R.↗
NASA NTRS1981

Orientation dependence of the stress rupture properties of Nickel-base superalloy single crystals

The influence of orientation of the stress rupture behavior of Mar-M247 single crystals was studied. Stress rupture tests were performed at 724 MPa and 774 C where the effect of anisotropy is prominent. The mechanical behavior of the single crystals was rationalized on the basis of the Schmid factors for the operative slip systems and the lattice rotations which the crystals underwent during deformation. The stress rupture lives were found to be greatly influenced by the lattice rotations required to produce intersecting slip, because steady-state creep does not begin until after the onset of intersecting slip. Crystals which required large rotations to become oriented for intersecting slip exhibited a large primary creep strain, a large effective stress level at the onset of steady-state creep, and consequently a short stress rupture life. A unified analysis was attained for the stress rupture behavior of the Mar-M247 single crystals tested in this study at 774 C and that of the Mar-M200 single crystals tested in a prior study at 760 C. In this analysis, the standard 001-011-111 stereographic triangle was divided into several regions of crystallographic orientation which were rank ordered according to stress rupture life for this temperature regime. This plot indicates that those crystals having orientations within about 25 deg of the 001 exhibited significantly longer lives when their orientations were closer to the 001-011 boundary of the stereographic triangle than to the 001-111 boundary.

Mackay, R. A.↗
NASA NTRS1996

Systematic Underestimation of Earthquake Magnitudes from Large Intracontinental Reverse Faults: Historical Ruptures Break Across Segment Boundaries

Because most large-magnitude earthquakes along reverse faults have such irregular and complicated rupture patterns, reverse-fault segments defined on the basis of geometry alone may not be very useful for estimating sizes of future seismic sources. Most modern large ruptures of historical earthquakes generated by intracontinental reverse faults have involved geometrically complex rupture patterns. Ruptures across surficial discontinuities and complexities such as stepovers and cross-faults are common. Specifically, segment boundaries defined on the basis of discontinuities in surficial fault traces, pronounced changes in the geomorphology along strike, or the intersection of active faults commonly have not proven to be major impediments to rupture. Assuming that the seismic rupture will initiate and terminate at adjacent major geometric irregularities will commonly lead to underestimation of magnitudes of future large earthquakes.

Rubin, C. M.↗
NASA NTRS2007

Strain Measurement Using FBG on COPV in Stress Rupture Test

White Sands Test Facility (WSTF) was requested to perform ambient temperature hydrostatic pressurization testing of a Space Transportation System (STS) 40-in. Kevlar Composite Overwrapped Pressure Vessel (COPV). The 40-in. vessel was of the same design and approximate age as the STS Main Propulsion System (MPS) and Orbiter Maneuvering System (OMS) vessels. The NASA Engineering Safety Center (NESC) assembled a team of experts and conducted an assessment that involved a review of national Kevlar COPY data. During the review, the STS COPVs were found to be beyond their original certification of ten years. The team observed that the likelihood of STS COPV Stress rupture, a catastrophic burst before leak failure mode, was greater than previously believed. Consequently, a detailed assessment of remaining stress rupture life became necessary. Prior to STS-114, a certification deviation was written for two flights of OV-103 (Discovery) and OV-104 (Atlantis) per rationale that was based on an extensive review of the Lawrence Livermore National Laboratories, COPV data, and revisions to the STS COPV stress levels. In order to obtain flight rationale to extend the certification deviation through the end of the Program, the Orbiter Project Office has directed an interagency COPV team to conduct further testing and analysis to investigate conservatism in the stress rupture model and evaluate material age degradation. Additional analysis of stress rupture life requires understanding the fiber stresses including stress that occurs due to thru-wall composite compression in COPV components. Data must be obtained at both zero gauge pressure (pre-stress) and at the component operating pressure so that this phenomenon can be properly evaluated. The zero gauge pressure stresses are predominantly a result of the autofrettage process used during vessel manufacture. Determining these pre-stresses and the constitutive behavior of the overwrap at pressure will provide necessary information to better predict the remaining life of the STS COPVs. The primary test objective is obtaining data to verify the hypothesis of a radially oriented thru-thickness stress-riser in the COPV composite whose magnitude is a function of the applied pressure and the load history. The anticipated load dependent response follows from the constitutive behavior of the composite overwrap so data to quantify its nonlinear and time dependent response will be sought. The objective of the Fiber Braggs Gratings (FBGs) were to advance the state-of-the-art by developing techniques using FBG sensors that are capable of assessing stress-rupture degradation in Kevlar COPVs in a health monitoring mode (1). Moreover, they sought to answer questions of how embedded sensors affect overall integrity of the structure. And lastly, they sought to provide an important link in the overall stress rupture study that will help close the loop on the COPV fabrication process. NDE inspection methods will be used from start to finish and FBG will be an integral link within the overall chain.

Banks, Curtis↗
NASA NTRS1982

The influence of orientation on the stress rupture properties of nickel-base superalloy single crystals

Constant load creep rupture tests were performed on MAR-M247 single crystals at 724 MPa and 774 C where the effect of anisotropy is prominent. The initial orientations of the specimens as well as the final orientations of selected crystals after stress rupture testing were determined by the Laue back-reflection X-ray technique. The stress rupture lives of the MAR-M247 single crystals were found to be largely determined by the lattice rotations required to produce intersecting slip, because second-stage creep does not begin until after the onset of intersecting slip. Crystals which required large rotations to become oriented for intersecting slip exhibited the shortest stress rupture lives, whereas crystals requiring little or no rotations exhibited the lowest minimum creep rates, and consequently, the longest stress rupture lives.

Mackay, R. A.↗
NASA NTRS1986

Creep-rupture and fractographic analysis of Stirling engine superalloys tested in air and 15 MPa hydrogen

A brief comparative analytical and microstructural evaluation of creep-rupture performance of two iron-base superalloys in air and 15 MPa of hydrogen, is presented. Creep rupture data are presented for the sheet alloy 19-9DL and the cast alloy XF-818, including temperature, initial stress, rupture life, minimum creep rate, time to reach one percent creep strain, and total elongation. In 19-9DL, both rupture life and minimum creep rate are more sharply dependent on small stress changes than in XF-818 in the given environment, and 19-9DL appears to become a more creep-resistant material with increasing Q (apparent activation energy) while the opposite is noted for XF-818. There appears to be no environmental effect on minimum creep rate for 19-9DL, whereas Q becomes less negative for XF-818 for 15 MPa of H2. Multiple cracks leading to rupture are observed on the fracture surfaces, with sheet specimens showing many more cracks close to the fracture surface than cast specimens.

Bhattacharyya, S.↗
NASA NTRS1988

Creep rupture analysis of a beam resting on high temperature foundation

A simplified uniaxial strain controlled creep damage law is deduced with the use of experimental observation from a more complex strain dependent law. This creep damage law correlates the creep damage, which is interpreted as the density variation in the material, directly with the accumulated creep strain. Based on the deduced uniaxial strain controlled creep damage law, a continuum mechanical creep rupture analysis is carried out for a beam resting on a high temperature elastic (Winkler) foundation. The analysis includes the determination of the nondimensional time for initial rupture, the propagation of the rupture front with the associated thinning of the beam, and the influence of creep damage on the deflection of the beam. Creep damage starts accumulating in the beam as soon as the load is applied, and a creep rupture front develops at and propagates from the point at which the creep damage first reaches its critical value. By introducing a series of fundamental assumptions within the framework of technical Euler-Bernoulli type beam theory, a governing set of integro-differential equations is derived in terms of the nondimensional bending moment and the deflection. These governing equations are subjected to a set of interface conditions at the propagating rupture front. A numerical technique is developed to solve the governing equations together with the interface equations, and the computed results are presented and discussed in detail.

Gu, Randy J.↗