Development of a nickel-base superalloy using statistically designed experiments.
Statistical techniques to develop nickel base superalloy with high temperature capabilities for jet engine turbine bucket applications
Collins, H. E.↗
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The application of statistically designed experiments to resistance spot welding
State-of-the-art Resistance Spot Welding (RSW) equipment has the potential to permit realtime monitoring of operations through advances in computerized process control. In order to realize adaptive feedback capabilities, it is necessary to establish correlations among process variables, welder outputs, and weldment properties. The initial step toward achieving this goal must involve assessment of the effect of specific process inputs and the interactions among these variables on spot weld characteristics. This investigation evaluated these effects through the application of a statistically designed experiment to the RSW process. A half-factorial, Taguchi L sub 16 design was used to understand and refine a RSW schedule developed for welding dissimilar aluminum-lithium alloys of different thickness. The baseline schedule had been established previously by traditional trial and error methods based on engineering judgment and one-factor-at-a-time studies. A hierarchy of inputs with respect to each other was established, and the significance of these inputs with respect to experimental noise was determined. Useful insight was gained into the effect of interactions among process variables, particularly with respect to weldment defects. The effects of equipment related changes associated with disassembly and recalibration were also identified. In spite of an apparent decrease in equipment performance, a significant improvement in the maximum strength for defect-free welds compared to the baseline schedule was achieved.
Hafley, Robert A.↗
The effects of Cr, Co, Al, Mo and Ta on the cyclic oxidation behavior of a prototype cast Ni-base superalloy based on a 2(5) composite statistically designed experiment
A series of cast Ni-base superalloys were systematically varied at selected levels of Co, Cr, Mo, Ta, and Al. The elemental levels varied were Mo, 0 to 4 percent; Cr, 6 to 18 percent; Co, 0 to 20 percent, Ta, 0 to 8 percent; and Al, 3.25 to 6.25 percent. The cyclic oxidation resistance was determined from specific weight change data as a function of time for 1 hr cycles in static air at 1100 C. The significant terms in decreasing order of their importance were Al, Ta, Cr2, Al-Cr, Cr-Co, Co2, Al-Mo, Cr-Mo, Al-Al, and Mo-Ta. The Al term alone accounted for close to 82 percent of the explained variability. The estimating equation showed that the Al level was the most important and should be at its 6.25 wt % maximum value. The Mo and Ta levels should also be at their maximum 4 and 8 wt % respectively. The cobalt composition should be as low as possible, i.e., 0 wt%. The Cr level optimum varies depending on the other 4 levels. The X-ray diffaction results indicate the most protective scales are alumina/aluminate spinel stabilizized with a tri-rutile oxide high in Ta and Mo.
Barrett, C. A.↗
SSSFD manipulator engineering using statistical experiment design techniques
The Satellite Servicer System Flight Demonstration (SSSFD) program is a series of Shuttle flights designed to verify major on-orbit satellite servicing capabilities, such as rendezvous and docking of free flyers, Orbital Replacement Unit (ORU) exchange, and fluid transfer. A major part of this system is the manipulator system that will perform the ORU exchange. The manipulator must possess adequate toolplate dexterity to maneuver a variety of EVA-type tools into position to interface with ORU fasteners, connectors, latches, and handles on the satellite, and to move workpieces and ORUs through 6 degree of freedom (dof) space from the Target Vehicle (TV) to the Support Module (SM) and back. Two cost efficient tools were combined to perform a study of robot manipulator design parameters. These tools are graphical computer simulations and Taguchi Design of Experiment methods. Using a graphics platform, an off-the-shelf robot simulation software package, and an experiment designed with Taguchi's approach, the sensitivities of various manipulator kinematic design parameters to performance characteristics are determined with minimal cost.
Barnes, John↗
Case Studies for the Statistical Design of Experiments Applied to Powered Rotor Wind Tunnel Tests
The application of statistical Design of Experiments (DOE) to helicopter wind tunnel testing was explored during two powered rotor wind tunnel entries during the summers of 2012 and 2013. These tests were performed jointly by the U.S. Army Aviation Development Directorate Joint Research Program Office and NASA Rotary Wing Project Office, currently the Revolutionary Vertical Lift Project, at NASA Langley Research Center located in Hampton, Virginia. Both entries were conducted in the 14- by 22-Foot Subsonic Tunnel with a small portion of the overall tests devoted to developing case studies of the DOE approach as it applies to powered rotor testing. A 16-47 times reduction in the number of data points required was estimated by comparing the DOE approach to conventional testing methods. The average error for the DOE surface response model for the OH-58F test was 0.95 percent and 4.06 percent for drag and download, respectively. The DOE surface response model of the Active Flow Control test captured the drag within 4.1 percent of measured data. The operational differences between the two testing approaches are identified, but did not prevent the safe operation of the powered rotor model throughout the DOE test matrices.
Overmeyer, Austin D.↗
Experiences in the Practice of Design of Experiments at NASA
Statistical design of experiments (DOE) has gained recognition within NASA by spurring innovation and efficiency, and it has demonstrated significant impact. Aerospace research and development benefits DOE techniques by accelerating learning, maximizing knowledge, ensuring strategic resource investment, and informing data-driven decisions. In practice, DOE relies on multidisciplinary collaboration to develop solution strategies that integrate statistical methods with subject-matter expertise to meet challenging research objectives. This presentation shares experiences in the practice of design of experiments at NASA in aeronautics, space exploration, and atmospheric science.
Peter A. Parker↗
Development of superalloys by powder metallurgy for use at 1000 - 1400 F
Consolidated powders of four nickel-base superalloys were studied for potential application as compressor and turbine discs in jet engines. All of the alloys were based on the Rene' 95 chemistry. Three of these had variations in carbon and A12O3 contents, and the fourth alloy was chemically modified to a higher volume fraction. The A12O3 was added by preoxidation of the powders prior to extrusion. Various levels of four experimental factors (1) alloy composition, (2) grain size, (3) thermomechanical processing, and (4) room temperature deformation plus final age were evaluated by tensile and stress rupture testing at 1200 F. Various levels of the four factors were assumed in order to construct the statistically-designed experiment, but the actual levels investigated were established in preliminary studies that preceded the statistical process development study.
Calhoun, C. D.↗
A designed experiment in stitched/RTM composites
The damage tolerance of composite laminates can be significantly improved by the addition of through-the-thickness fibrous reinforcement such as stitching. However, there are numerous stitching parameters which can be independently varied, and their separate and combined effects on mechanical properties need to be determined. A statistically designed experiment (a 2(sup 5-1) fractional factorial, also known as a Taguchi L16 test matrix) used to evaluate five important parameters is described. The effects and interactions of stitch thread material, stitch thread strength, stitch row spacing and stitch pitch are examined for both thick (48 ply) and thin (16 ply) carbon/epoxy (AS4/E905L) composites. Tension, compression and compression after impact tests are described. Preliminary results of completed tension testing are discussed. Larger threads decreased tensile strength. Panel thickness was found not to be an important stitching parameter for tensile properties. Tensile modulus was unaffected by stitching.
Dickinson, Larry C.↗
Maximizing Macromolecule Crystal Size for Neutron Diffraction Experiments
A challenge in neutron diffraction experiments is growing large (greater than 1 cu mm) macromolecule crystals. In taking up this challenge we have used statistical experiment design techniques to quickly identify crystallization conditions under which the largest crystals grow. These techniques provide the maximum information for minimal experimental effort, allowing optimal screening of crystallization variables in a simple experimental matrix, using the minimum amount of sample. Analysis of the results quickly tells the investigator what conditions are the most important for the crystallization. These can then be used to maximize the crystallization results in terms of reducing crystal numbers and providing large crystals of suitable habit. We have used these techniques to grow large crystals of Glucose isomerase. Glucose isomerase is an industrial enzyme used extensively in the food industry for the conversion of glucose to fructose. The aim of this study is the elucidation of the enzymatic mechanism at the molecular level. The accurate determination of hydrogen positions, which is critical for this, is a requirement that neutron diffraction is uniquely suited for. Preliminary neutron diffraction experiments with these crystals conducted at the Institute Laue-Langevin (Grenoble, France) reveal diffraction to beyond 2.5 angstrom. Macromolecular crystal growth is a process involving many parameters, and statistical experimental design is naturally suited to this field. These techniques are sample independent and provide an experimental strategy to maximize crystal volume and habit for neutron diffraction studies.
Judge, R. A.↗
Organometallic Polymeric Conductors
For aerospace applications, the use of polymers can result in tremendous weight savings over metals. Suitable polymeric materials for some applications like EMI shielding, spacecraft grounding, and charge dissipation must combine high electrical conductivity with long-term environmental stability, good processability, and good mechanical properties. Recently, other investigators have reported hybrid films made from an electrically conductive polymer combined with insulating polymers. In all of these instances, the films were prepared by infiltrating an insulating polymer with a precursor for a conductive polymer (either polypyrrole or polythiophene), and oxidatively polymerizing the precursor in situ. The resulting composite films have good electrical conductivity, while overcoming the brittleness inherent in most conductive polymers. Many aerospace applications require a combination of properties. Thus, hybrid films made from polyimides or other engineering resins are of primary interest, but only if conductivities on the same order as those obtained with a polystyrene base could be obtained. Hence, a series of experiments was performed to optimize the conductivity of polyimide-based composite films. The polyimide base chosen for this study was Kapton. 3-MethylThiophene (3MT) was used for the conductive phase. Three processing variables were identified for producing these composite films, namely time, temperature, and oxidant concentration for the in situ oxidation. Statistically designed experiments were used to examine the effects of these variables and synergistic/interactive effects among variables on the electrical conductivity and mechanical strength of the films. Multiple linear regression analysis of the tensile data revealed that temperature and time have the greatest effect on maximum stress. The response surface of maximum stress vs. temperature and time (for oxidant concentration at 1.2 M) is shown. Conductivity of the composite films was measured for over 150 days in air at ambient temperature. The conductivity of the films dropped only half an order of magnitude in that time. Films aged under vacuum at ambient temperature diminished slightly in conductivity in the first day, but did not change thereafter. An experimental design approach will be applied to maximize the efficiency of the laboratory effort. The material properties (initial and long term) will also be monitored and assessed. The experimental results will add to the existing database for electrically conductive polymer materials. Attachments: 1) Synthesis Crystal Structure, and Polymerization of 1,2:5,6:9,10-Tribenzo-3,7,11,13-tetradehydro(14) annulene. 2) Reinvestigation of the Photocyclization of 1,4-Phenylene Bis(phenylmaleic anhydride): Preparation and Structure of (5)Helicene 5,6:9,10-Dianhydride. 3) Preparation and Structure Charecterization of a Platinum Catecholate Complex Containing Two 3-Ethynyltheophone Groups. and 4) Rigid-Rod Polymers Based on Noncoplanar 4,4'-Biphenyldiamines: A Review of Polymer Properties vs Configuration of Diamines.
Youngs, Wiley J.↗
Laser diode initiated detonators for space applications
Ensign Bickford Aerospace Company (EBAC) has over ten years of experience in the design and development of laser ordnance systems. Recent efforts have focused on the development of laser diode ordnance systems for space applications. Because the laser initiated detonators contain only insensitive secondary explosives, a high degree of system safety is achieved. Typical performance characteristics of a laser diode initiated detonator are described in this paper, including all-fire level, function time, and output. A finite difference model used at EBAC to predict detonator performance, is described and calculated results are compared to experimental data. Finally, the use of statistically designed experiments to evaluate performance of laser initiated detonators is discussed.
Ewick, David W.↗
Factors affecting laser-trim stability of thick film resistors
Various factors affecting precision of trim and resistor stability were considered. The influence of machine operating parameters on resistor performance was examined and quantified through statistically designed experiments for a Q switched YAG laser system. Laser kerf quality was studied by scanning electron microscopy and related to kerf isolation resistance measurements. A relatively simple production oriented, quality control test is proposed for rapid determination of kerf electrical stability. In addition, the effect of cut design and extent of trim on precision and stability were discussed.
Cote, R. E.↗
Parametric evaluation of ball milling of SiC in water
A statistically designed experiment was conducted to determine optimum conditions for ball milling alpha-SiC in water. The influence of pH adjustment, volume percent solids loading, and mill rotational speed on grinding effectiveness was examined. An equation defining the effect of those milling variables on specific surface area was obtained. The volume percent solids loading of the slurry had the greatest influence on the grinding effectiveness in terms of increase in specific surface area. As grinding effectiveness improved, mill and media wear also increased. Contamination was minimized by use of sintered alpha-SiC milling hardware.
Kiser, J. D.↗
Parametric evaluation of ball milling of SiC in water
A statistically designed experiment was conducted to determine optimum conditions for ball milling alpha-SiC in water. The influence of pH adjustment, volume percent solids loading, and mill rotational speed on grinding effectiveness was examined. An equation defining the effect of those milling variables on specific surface area was obtained. The volume percent solids loading of the slurry had the greatest influence on the grinding effectiveness in terms of increase in specific surface area. As grinding effectiveness improved, mill and media wear also increased. Contamination was minimized by use of sintered alpha-SiC milling hardware.
Kiser, J. D.↗
Improved silicon carbide for advanced heat engines. I - Process development for injection molding
Alternate processing methods have been investigated as a means of improving the mechanical properties of injection-molded SiC. Various mixing processes (dry, high-sheer, and fluid) were evaluated along with the morphology and particle size of the starting beta-SiC powder. Statistically-designed experiments were used to determine significant effects and interactions of variables in the mixing, injection molding, and binder removal process steps. Improvements in mechanical strength can be correlated with the reduction in flaw size observed in the injection molded green bodies obtained with improved processing methods.
Whalen, Thomas J.↗
Improved silicon carbide for advanced heat engines
This is the third annual technical report for the program entitled, Improved Silicon Carbide for Advanced Heat Engines, for the period February 16, 1987 to February 15, 1988. The objective of the original program was the development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines. Injection molding is the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals of the revised program are to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in 4-point loading. Two tasks are discussed: Task 1 which involves materials and process improvements, and Task 2 which is a MOR bar matrix to improve strength and reliability. Many statistically designed experiments were completed under task 1 which improved the composition of the batches, the mixing of the powders, the sinter and anneal cycles. The best results were obtained by an attritor mixing process which yielded strengths in excess of 550 MPa (80 ksi) and an individual Weibull modulus of 16.8 for a 9-sample group. Strengths measured at 1200 and 1400 C were equal to the room temperature strength. Annealing of machined test bars significantly improved the strength. Molding yields were measured and flaw distributions were observed to follow a Poisson process. The second iteration of the Task 2 matrix experiment is described.
Whalen, Thomas J.↗
Improved silicon carbide for advanced heat engines
The development of high strength, high reliability silicon carbide parts with complex shapes suitable for use in advanced heat engines is studied. Injection molding was the forming method selected for the program because it is capable of forming complex parts adaptable for mass production on an economically sound basis. The goals were to reach a Weibull characteristic strength of 550 MPa (80 ksi) and a Weibull modulus of 16 for bars tested in four-point loading. Statistically designed experiments were performed throughout the program and a fluid mixing process employing an attritor mixer was developed. Compositional improvements in the amounts and sources of boron and carbon used and a pressureless sintering cycle were developed which provided samples of about 99 percent of theoretical density. Strengths were found to improve significantly by annealing in air. Strengths in excess of 550 MPa (80 ksi) with Weibull modulus of about 9 were obtained. Further improvements in Weibull modulus to about 16 were realized by proof testing. This is an increase of 86 percent in strength and 100 percent in Weibull modulus over the baseline data generated at the beginning of the program. Molding yields were improved and flaw distributions were observed to follow a Poisson process. Magic angle spinning nuclear magnetic resonance spectra were found to be useful in characterizing the SiC powder and the sintered samples. Turbocharger rotors were molded and examined as an indication of the moldability of the mixes which were developed in this program.
Whalen, Thomas J.↗
Statistical design study of lunar ceramic
Fabrication of a lunar ceramic was conducted according to a statistically designed experiment. The method of cold pressing was used since the consumption of electrical energy is kept to a minimum (a priority in the lunar environment). This traditional fabrication technique also provides an initial data source on which further investigations can be based. Results obtained from using two percent binder, a cold pressing pressure of 276 MPa, and 24 hours sintering time yielded the greatest compressive strength of 247 MPa. Analysis of each variable's influence on the compressive strength is also presented.
Effinger, Mike↗