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Stress corrosion evaluation of HP 9Ni-4Co-0.30C steel plate welds

A stress corrosion cracking (SCC) investigation was conducted on HP 9Ni-4Co-0.30C steel plate welds (welded by using straight polarity plasma arc and HP 9Ni-4Co-0.20C weld wire) since this material is being considered for use in the Advanced Solid Rocket Motor (ASRM) program. Prior to the welding, the material was double tempered at 538 C (1,000 F). After welding, only part of the material was stress relieved at 510 C (950 F) for 3 h. Round tensile specimens obtained from nonstress-relieved material were tested in 100-percent relative humidity at 38 C (100 F), in 3.5-percent NaCl alternate immersion, and in 5-percent salt spray at 35 C (95 F). Specimens obtained from stress-relieved material were tested in alternate immersion. The stress levels were 50, 75, and 90 percent of the corresponding 0.2-percent yield strength (YS). All the nonstress-relieved specimens exposed to salt spray and alternate immersion failed. Stress-relieved specimens (exposed to alternate immersion) failed at 75 and 90 percent of YS. No failures occurred at 50 percent of YS in the stress-relieved specimens which indicates a beneficial effect of the stress relief on the SCC resistance of these welds. The stress relief also had a positive effect on the mechanical properties of the welds (the most important being an increase of 21 percent on the YS). Under the conditions of these tests, the straight polarity plasma are welded HP 9Ni4Co-0.30C steel plate was found highly susceptible to SCC in the nonstress-relieved condition. This susceptibility to SCC was reduced by stress relieving.

Torres, Pablo D.↗

A Review of the Proposed K (sub Isi) Offset-Secant Method for Size-Independent Linear-Elastic Toughness Evaluation

The proposed size-independent linear-elastic fracture toughness, K (sub Isi), for potential inclusion in ASTM E399 targets a consistent 0.5 millimeters crack extension for all specimen sizes through an offset secant that is a function of the specimen ligament length. The K (sub Isi) method also includes an increase in allowable deformation, and the removal of the P (sub max)/P (sub Q) criterion. A finite element study of the K (sub Isi) test method confirms the viability of the increased deformation limit, but has also revealed a few areas of concern. Findings: 1. The deformation limit, b (sub o) greater than or equal to 1.1 times (K (sub I) divided by delta (sub ys) squared) maintains a K-dominant crack tip field with limited plastic contribution to the fracture energy; 2. The three dimensional effects on compliance and the shape of the force versus CMOD (Crack-Mouth Opening Displacement) trace are significant compared to a plane strain assumption; 3. The non-linearity in the force versus CMOD trace at deformations higher than the current limit of 2.5 times (K (sub I) divided by delta (sub ys) squared) is sufficient to introduce error or even "false calls" regarding crack extension when using a constant offset secant line. This issue is more significant for specimens with W (width) greater than or equal to 2 inches; 4. A non-linear plasticity correction factor in the offset secant may improve the viability of the method at deformations between 2.5 times (K (sub I) divided by delta (sub ys) squared) and 1.1 times (K (sub I) divided by delta (sub ys) squared).

James, Mark↗

Climatic Versus Biotic Constraints on Carbon and Water Fluxes in Seasonally Drought-affected Ponderosa Pine Ecosystems

We investigated the relative importance of climatic versus biotic controls on gross primary production (GPP) and water vapor fluxes in seasonally drought-affected ponderosa pine forests. The study was conducted in young (YS), mature (MS), and old stands (OS) over 4 years at the AmeriFlux Metolius sites. Model simulations showed that interannual variation of GPP did not follow the same trends as precipitation, and effects of climatic variation were smallest at the OS ( 50%), and intermediate at the YS (<20%). In the young, developing stand, interannual variation in leaf area has larger effects on fluxes than climate, although leaf area is a function of climate in that climate can interact with age-related shifts in carbon allocation and affect whole-tree hydraulic conductance. Older forests, with well-established root systems, appear to be better buffered from effects of seasonal drought and interannual climatic variation. Interannual variation of net ecosystem exchange (NEE) was also lowest at the OS, where NEE is controlled more by interannual variation of ecosystem respiration, 70% of which is from soil, than by the variation of GPP, whereas variation in GPP is the primary reason for interannual changes in NEE at the YS and MS. Across spatially heterogeneous landscapes with high frequency of younger stands resulting from natural and anthropogenic disturbances, interannual climatic variation and change in leaf area are likely to result in large interannual variation in GPP and NEE.

Schwarz, P. A.↗

Deoxypyridinoline in the Urine of Rats with Unloaded Hindlimbs

The urinary excretion of deoxypyridinoline (U-Dpd), a nonreducible collagen crosslink in bone released by osteoclastic activity, is thought to be an accurate marker of bone resorption. The role of increased resorption in the osteopenia of a space flight model which unloads the hindlimbs by suspending the tail is controversial. To assess skeletal resorption in the model we measured U-Dpd (Pyrilinks-D, Metro Biosystems, Inc.) in serial 24 hour urine specimens collected from 250 a (Y) and 450 a (M) male rats with unloaded hindlimbs for four weeks. Both groups of rats were fed AIN76 diets with calcium restricted to 0.2% in Y and to 0.1 % in M. Blood was obtained after 28 days for parathyroid hormone (PTH), 1,25-dihydroxyvitamin D (1,25-D) and alkaline phosphatase (Alkptase). Basal U-Dpd was higher and more variable in Y than M (475+/-200 vs 67+/-9, nM/mM creatinine, p<.001). Repeated measures ANOVA in Y revealed decreases in U-Dpd, 36% in control (C) and 24% in unloaded (S) rats (p<.005). There was a nadir in YS on the 14th day not observed in YC (p<.05). U-Dpd in MC showed no change, but increased in MS by the 14th day and remained elevated. At the end of the experiment, body weights in both Y and M were less in S than C (337+/-16 vs 306+/-12g and 485+/-10 vs 461+/-6g, p=.002). Bill was inversely related to U-Dpd only in M (r=0.699, p=.024). PTH, similar in C and S in Y (52+/-15 vs 42+/-7pg/ml, NS) and M (68+/-13 vs 61+/-12, NS), was unrelated to U-Dpd. 1,25-D tended toward higher values in YC than YS (197+/-103 vs 119+/-30, NS) and correlated with U-Dpd (0.773, p=.015). Alkptase, 1.3 times higher in Y than M, was similar in C and S at the end of unloading. These findings indicate that bone resorption, as reflected by U-Dpd, is suppressed in young and stimulated in mature rats exposed to a space flight model. U-Dpd reflects reduced growth from the diet change in young control and experimental rats and loss of Bill in mature animals exposed to the space flight model, 2 situations with opposite effects on bone resorption.

Arnaud, Sara B.↗

Flexural Fatigue Testing and Qualification of Hybrid PAN-pitch Composite Materials with High Through-Thickness Thermal Conductivity

Carbon-fiber-reinforced polymers (CFRPs) considered for motor components within future electric vertical takeoff and landing (eVTOL) vehicles require not only a high strength-to-weight ratio but also a high through-thickness thermal conductivity (TC) to dissipate heat. Previously, CFRPs incorporating pitch CF interleaves demonstrated an increased through-thickness TC relative to the baseline composite, but the effect on flexural fatigue life was not evaluated. For this work, T700S/TC275–1 braided carbon fiber/epoxy prepreg baseline (no interleave), YSH–60A pitch interleave, and YS–80A pitch interleave configurations were tested for fatigue life. A combination of ASTM International Standards D7264 and D3479 were used to develop a reliable testing method. An Instron® (Illinois Tool Works Inc.) 8501 servohydraulic system with a fatigue test fixture was set up with a 16:1 span:thickness ratio, load ratio R set to 0.1, and frequency of 4 Hz. High-cycle fatigue testing was completed, and it was found that YSH–60A interleave performed slightly better than YS–80A below 100,000 cycles but showed no differences above 100,000 cycles. In all cases, the baseline CFRP had superior fatigue life performance both in terms of stress handled and total cycles to failure. These fatigue testing data will inform future use of hybrid CFRP materials by highlighting the tradeoff between increased through-thickness TC and fatigue life. Testing guidelines, equipment, and parameters for static and fatigue tests were successfully outlined for CFRPs.

composites↗

Considerations on repeated repairing of weldments in Inconel 718 alloy

The effects of repeated weld repairs on the metallurgical characteristics, high cycle fatigue (HCF), and tensile properties of Inconel 718 butt weld joints were determined. A 1/4 in thick plate and a 1/2 in thick plate were used as well as tungsten inert gas welding, and Inconel 718 filler wire. Weld panels were subjected to 2, 6, and 12 repeated repairs and were made in a highly restrained condition. Post weld heat treatments were also conducted with the welded panel in the highly restrained condition. Results indicate that no significant metallurgical anomaly is evident as a result of up to twelve repeated weld repairs. No degradation in fatigue life is noted for up to twelve repeated repairs. Tensile results from specimens which contained up to twelve repeated weld repairs revealed no significant degradation in UTS and YS. However, a significant decrease in elongation is evident with specimens (solution treated and age hardened after welding) which contained twelve repeated repairs. The elongation loss is attributed to the presence of a severe notch on each side (fusion line) of the repair weld bead reinforcement.

Bayless, E. O.↗

Theoretical studies of the monoxides and monosulfides of Y, Zr, and Nb

Modified-CPF and CASSCF/multireference-CI theoretical calculations are presented for the ground and low-lying states of YO and YS, ZrO and ZS, and NbO and NbS. The techniques employed are explained, and the calculated spectroscopic constants are presented in extensive tables. Good agreement is found with published experimental data on the oxides, and it is inferred that the sulfide results are accurate as well. Particular attention is given to the high-lying quartet manifold of states in YO and the (1) 3Pi-a3Delta transition of ZrS (possibly the source of the IR Keenan bands seen in S-star spectra).

Langhoff, Stephen R.↗

Structure and properties during aging of an Al-Cu-Li-Ag-Mg alloy, Weldalite (tm) 049

An Al-Cu-Li-Ag-Mg alloy, Weldalite (trademark) 049, was recently introduced as an ultra-high strength alloy (7000 MPa yield strength in artificially aged tempers) with good weldability. In addition, the alloy exhibits an extraordinary natural aging response (440 MPa yield strength (YS) in the unstretch condition) and a high ductility reversion condition which may be useful as a cold-forming temper. In contrast to other Al-Li alloys, these properties can essentially be obtained with or without a stretch or other coldworking operation prior to aging. Preliminary studies have revealed that the T4 temper (no stretch, natural age) is strengthened by a combination of GP zones and delta prime (Al3Li). The T6 temper (no stretch, aged at 180 C to peak strength) was reported to be strengthened primarily by T(sub 1) phase (Al2CuLi) with a minor presence of a theta prime like (Al2Cu) phase. On the other hand, a similar but lower solute containing alloy was reported to contain omega, (stoichiometry unknown), theta prime, and S prime in the peak strength condition. The purpose of this study is to further elucidate the strengthening phases in Weldalite (trademark) 049 in the unstretched tempers, and to follow the development of the microstructure from the T4 temper through reversion (180 C for 5 to 45 minutes) to the T6 temper.

Gayle, Frank W.↗

Microstructural evolution during aging of an Al-Cu-Li-Ag-Mg-Zr alloy

Alloys in the Al-Cu-Li Ag-Mg subsystem were developed that exhibit desirable combinations of strength and ductility. These Weldalite (trademark) alloys, are unique for Al-Cu-Li alloys in that with or without a prior cold stretching operation, they obtain excellent strength-ductility combinations upon natural and artificial aging. This is significant because it enables complex, near-net shape products such as forgings and super plastically formed parts to be heat treated to ultra-high strengths. On the other hand, commercial extrusions, rolled plates and sheets of other Al-Cu-Li alloys are typically subjected to a cold stretching operation before artificial aging to the highest strength tempers to introduce dislocations that provide low-energy nucleation sites for strengthening precipitates such as the T(sub 1) phase. The variation in yield strength (YS) with Li content in the near-peak aged condition for these Weldalite (trademark) alloys and the associated microstructures were examined, and the results are discussed.

Kumar, K. S.↗

Sulfur and Moisture Effects on Alumina Scale and TBC Spallation

It has been well established that a few ppmw sulfur impurity may segregate to the interface of thermally grown alumina scales and the underlying substrate, resulting in bond degradation and premature spallation. This has been shown for NiAl and NiCrAl-based alloys, bare single crystal superalloys, or coated superalloys. The role of reactive elements (especially Y) has been to getter the sulfur in the bulk and preclude interfacial segregation. Pt additions are also very beneficial, however a similar thermodynamic explanation does not apply. The purpose of the present discussion is to highlight some observations of these effects on Rene'142, Rene'N5, PWA1480, and PWA1484. For PWA1480, we have mapped cyclic oxidation and spallation in terms of potential sulfur interfacial layers and found that a cumulative amount of about one monolayer is sufficient to degrade long term adhesion. Depending on substrate thickness, optimum performance occurs if sulfur is reduced below about 0.2-0.5 ppmw. This is accomplished in the laboratory by hydrogen annealing or commercially by melt-fluxing. Excellent 1150 C cyclic oxidation is thus demonstrated for desulfurized Rene'142, Rene'N5, and PWA1484. Alternatively, a series of N5 alloys provided by GE-AE have shown that as little as 15 ppmw of Y dopant was effective in providing remarkable scale adhesion. In support of a Y-S gettering mechanism, hydrogen annealing was unable to desulfurize these alloys from their initial level of 5 ppmw S. This impurity and critical doping level corresponds closely to YS or Y2S3 stoichiometry. In many cases, Y-doped alloys or alloys with marginal sulfur levels exhibit an oxidative sensitivity to the ambient humidity called Moisture-Induced Delayed Spallation (MIDS). After substantial scale growth, coupled with damage from repeated cycling, cold samples may spall after a period of time, breathing on them, or immersing them in water. While stress corrosion arguments may apply, we propose that the underlying cause is related to a hydrogen embrittlement reaction: Al alloy + 3 H2O = Al(OH)3 + 3H(+) + 3e(-). This mechanism is derived from an analogous moisture-induced hydrogen embrittlement mechanism originally shown for Ni3Al and FeAl intermetallics. Consequently, a cathodic hydrogen charging technique was used to demonstrate that electrolytic de-scaling occurs for these otherwise adherent alumina scales formed on Y-doped Rene'N5, in support of hydrogen effects. Finally, some TBC observations are discussed in light of all of the above. Plasma sprayed 8YSZ coatings, produced on PWA1484 without a bond coat, were found to survive more than 1000 1-hr cycles at 1100 C when desulfurized to below 0.1 ppmw. At higher sulfur (1.2 ppmw) levels, moisture sensitivity and delayed TBC failure, referred to as Desk Top Spallation, occurred at just 200 hr. Despite a large degree of scatter, a factor of 5 in life improvement is indicated for desulfurized samples in cyclic furnace tests, confirming the beneficial effect of low sulfur alloys on model TBC systems. (DTS and moisture effects are also observed on commercially applied PVD 7YSZ coatings on Rene'N5+Y with Pt-aluminide bond coats). These types of catastrophic failure were subverted on the model system by segmenting the substrate into a network of 0.010 high ribs, spaced in. apart, prior to plasma spraying. No failures occurred after 1000 cycles at 1150 C or after 2000 cycles at 1100 C, even after water immersion. The benefit is described in terms of elasticity models and a critical buckling stress.

Smialek, James L.↗

Repeatability and Reproducibility of Compression Strength Measurements Conducted According to ASTM E9

Ten commercial laboratories participated in an interlaboratory study to establish the repeatability and reproducibility of compression strength tests conducted according to ASTM International Standard Test Method E9. The test employed a cylindrical aluminum AA2024-T351 test specimen. Participants measured elastic modulus and 0.2 % offset yield strength, YS(0.2 % offset), using an extensometer attached to the specimen. The repeatability and reproducibility of the yield strength measurement, expressed as coefficient of variations were cv(sub r)= 0.011 and cv(sub R)= 0.020 The reproducibility of the test across the laboratories was among the best that has been reported for uniaxial tests. The reported data indicated that using diametrically opposed extensometers, instead of a single extensometer doubled the precision of the test method. Laboratories that did not lubricate the ends of the specimen measured yield stresses and elastic moduli that were smaller than those measured in laboratories that lubricated the specimen ends. A finite element analysis of the test specimen deformation for frictionless and perfect friction could not explain the discrepancy, however. The modulus measured from stress-strain data were reanalyzed using a technique that finds the optimal fit range, and applies several quality checks to the data. The error in modulus measurements from stress-strain curves generally increased as the fit range decreased to less than 40 % of the stress range.

Luecke, William E.↗

Failure Analysis of T-38 Aircraft Burst Hydraulic Aileron Return Line

During maintenance troubleshooting for fluctuating hydraulic pressures, a technician found that a right hand aileron return line, on the flight hydraulic side, was ruptured (Fig. 1, 2). This tubing is part of the Hydraulic Flight Control Aileron Return Reducer to Aileron Manifold and is suspected to be original to the T-38 Talon trainer aircraft. Ailerons are small hinged sections on the outboard portion of a wing used to generate rolling motion thereby banking the aircraft. The ailerons work by changing the effective shape of the airfoil of the outer portion of the wing [1]. The drawing, Northrop P/N 3-43033-55 (6/1960), specifies that the line is made from 0.375 inch OD, aluminum 5052-0 tubing with a 0.049 inch wall thickness. WW-T-787 requires the tube shall be seamless and uniform in quality and temper [2]. The test pressure for this line is 3000 psi, and the operational pressure for this line is estimated to be between 45 psi and 1500 psi based on dynamic loading during flight. Examination of the fracture surface found evidence of arrest bands originating on the inner diameter (Fig 3). Ductile dimples are observed on the tube fractures (Fig. 4). The etched cross-section revealed thinning and work-hardening in the burst region (Fig. 5). The wall thickness just outside the work-hardened fracture region measured 0.035". Barlow's Formula: P = 2St/D, where P is burst pressure, S is allowable stress, t is wall thickness and D is the outer diameter of tube. Using the ultimate tensile strength of 28 ksi and a measured wall thickness of 0.035 inches at burst, P = 5.2 ksi (burst pressure). Using the yield of 13 ksi (YS) for aluminum 5052-0, plastic deformation will happen at P = 2.4 ksi suggesting plastic deformation occurred at a proof pressure of 3.0 ksi. Conclusion: The burst resulted from high stress, low-cycle fatigue. Evidence of arrest bands originating on the inner diameter. Fracture is predominately shear dimples, characteristic of high load ductile fractures (Fig 6). Section wall reduction in the burst region. Plastic deformation and thinning of the out-of-specification tube wall likely happened during the initial proof testing years ago. Metallography of tubing away from rupture site confirmed tubing was seamless. Based on the tube microstructure, it is likely that the initial wall thickness was about 30 % thinner than the requirement of 0.049 inches. Fracture initiated on the ID and progressed to the OD (shear lip). The tube is made of the correct material of 5052-0 aluminum as verified using Optical Emission Spectroscopy (Table 2). The tubing hardness tested 77 HV100 (77 HRE). This hardness is slightly above the requirement for 70 HRE maximum for aluminum 5052-0 in AMS 2658C [3].

Martinez, J. E.↗

Evolution of the Climate Forcing During the Two Years after the Hunga Tonga-Hunga Ha’apai Eruption

We calculate the climate forcing for the 2 ys after the 15 January 2022, Hunga Tonga-Hunga Ha'apai (Hunga) eruption. We use satellite observations of stratospheric aerosols, trace gases and temperatures to compute the tropopause radiative flux changes relative to climatology. Overall, the net downward radiative flux decreased compared to climatology. The Hunga stratospheric water vapor anomaly initially increases the downward infrared radiative flux, but this forcing diminishes as the anomaly disperses. The Hunga aerosols cause a solar flux reduction that dominates the net flux change over most of the 2 yrs period. Hunga induced temperature changes produce a decrease in downward long-wave flux. Hunga induced ozone reduction increases the short-wave downward flux creating small sub-tropical increase in total flux from mid-2022 to 2023. By the end of 2023, most of the Hunga induced radiative forcing changes have disappeared. There is some disagreement in the satellite measured stratospheric aerosol optical depth (SAOD) observations which we view as a measure of the uncertainty; however, the SAOD uncertainty does not alter our conclusion that, overall, aerosols dominate the radiative flux changes.

M R Schoeberl↗

Objective Structured Clinical Evaluation (OSCE) of an Artificial Intelligence (AI) Clinical Decision Support System (CDSS) Tool

BACKGROUND Objective Structured Clinical Evaluations (OSCEs) have long been established as a robust methodology for summative assessment of clinical skills and decision-making during medical education. The recent integration of Artificial Intelligence (AI) into clinical decision-making processes has prompted the need for novel evaluation frameworks to assess the efficacy and reliability of AI clinical decision support system (CDSS) tools. This abstract outlines the process of quantitatively evaluating a novel CDSS (“Doc in a Box” Google 2024) trained on curated medical spaceflight data in the psychomotor domain as it interfaces with a human volunteer acting as the crew medical officer (CMO). PURPOSE The AI CDSS under review was developed as part of the Lunar Command and Control Interoperability (LuCCI) project, which is intended to address a gap in how Lunar Surface Systems (LSS) would interoperate across multiple programs, commercial partners, and international partners. The project objective is to define, prototype, integrate, and evaluate an interoperable lunar command, control, data, and software reference architecture to enable autonomy and informatics capability through common standards across LSS. A multi-modal AI-based CDSS compatible with Federated LSS will assist clinicians in diagnosing and managing complex medical conditions by providing evidence-based recommendations through predictive analytics. Given the critical role of decision-support as NASA continues to evolve its Earth-independent medical operations (EIMO), it is imperative to ensure that such AI tools perform reliably and align with clinical standards during progressive lunar and Martian exploration class missions. METHODS The OSCE framework, traditionally used for evaluating human clinicians, was adapted to assess the AI tool's decision-making capabilities in simulated clinical scenarios. In this adapted OSCE, the AI CDSS was tested across a series of structured clinical scenarios designed to mimic real-life spaceflight patient cases. These scenarios included a range of conditions and complexities, allowing for comprehensive assessment of the tool's performance. Key evaluation metrics included accuracy of diagnosis, timeliness of decision-making, and appropriate recommendations for therapies. The OSCE was scored by human physician evaluators who assessed the AI's recommendations in comparison with expert clinicians' medical decision making to ensure alignment with best practices and the standard of care. RESULTS Preliminary results indicate that the AI CDSS demonstrated high accuracy in diagnostic recommendations and decision support across various scenarios. However, certain limitations were noted, such as occasional discrepancies in handling complex or nuanced cases that required a more contextual understanding. Additionally, the tool scored higher on the diagnostic portion of the rubric, with lower scores in the therapeutic recommendations. These findings highlight the importance of continuous refinement and validation of AI tools through rigorous evaluation frameworks like the OSCE. The adaptation of OSCEs for AI tools presents several advantages, including a structured and reproducible approach to evaluation, the ability to test AI systems in diverse clinical scenarios, and the opportunity to benchmark AI performance against established clinical standards to permit charting of future progress as aerospace medicine evolves as a discipline. Remaining challenges include ensuring that these evaluations capture the full spectrum of clinical decision-making scenarios that will be confronted by CMOs during missions and adequately reflecting real-world variability of the austere spaceflight environment. CONCLUSION Employing OSCEs to evaluate AI clinical decision support tools offers a promising approach to validating their clinical utility and efficacy. This methodology not only provides insights into the tool's performance but also fosters ongoing improvement and alignment with standard of care practices. Future research should focus on refining these evaluation processes and addressing limitations to enhance the integration of AI tools in clinical spaceflight settings. REFERENCES Scott S, Hearns V, Barker MA. Testing Clinical Skills: A Look at the OSCE and USMLE Clinical Skills Exams. S D Med. 2019 Oct;72(10):451-453. Majumder MAA, Kumar A, Krishnamurthy K, Ojeh N, Adams OP, Sa B. An evaluative study of objective structured clinical examination (OSCE): students and examiners perspectives. Adv Med Educ Pract. 2019 Jun 5;10:387-397. Karam VY, Park YS, Tekian A, Youssef N. Evaluating the validity evidence of an OSCE: results from a new medical school. BMC Med Educ. 2018 Dec 20;18(1):313.

Ariana M Nelson↗