Engineering topics
Publications and source records attributed to Johnston, M. H..
Report describes experiments on directional solidification on MAR-M246(Hf) superalloy in low gravity. Determines effects of reduction in gravity on growth of dendrites and on resultant interdendritic segregation of various constituents, particularly of additive hafnium. Interdendritic spacings and carbide contents increase.
Fatigue properties degraded with crystallographic orientations greater than 10 degrees from {001} axis. Influence of solidification and heat-treatment parameters on structure and fatigue properties of nickel-based superalloy MAR-M246(Hf) described in 24-page report. Superalloys have high strength and corrosion resistance at temperatures up to 1,400 degrees C; their uses range from petrochemical equipment to marine, industrial, aircraft, and vehicular gas turbines.
Controlled solidification continued through many dives. Since each dive gives 20 to 30 seconds in which gravity is 0.001 to 0.1 its normal value, and aircraft may make about ten low-gravity maneuvers in mission, technique allows substantial time to conduct a low-gravity experiment. In directional solidification, liquid/solid interface advanced slowly through rod of sample alloy. Solidification continues during several aircraft maneuvers. Known solidification rate of sample correlated with accelerometer data to find gravity value during solidification for any point in sample. Thermal gradient and solidification rate controlled independently.
Crystal observed as it grows from melt with aid of laser schlieren imaging. Observation method allows entire perimeter of growing crystal to be inspected. Isolated crystal facets examined, convection flows and temperature and concentration gradients revealed. Method does not require contact with, or proximity to, crystal.
The Ni-base superalloy MAR-M246 (Hf) was directionally solidified during low gravity maneuvers aboard a NASA KC-135 aircraft. Gravity force variations during this process yielded a concomitant variation in microstructure and microsegregation. Secondary dendrite arm spacings are noted to be larger in the low-g portion; this, in turn, decreases the extent of interdendritic segregation. The amount of Hf in both the carbides and interdendritic eutectic increases as the gravity force diminishes. Fewer carbides are present in the low-g regions.
This research analyzes four areas: (1) Improved Techniques for Optical Measurement; (2) KC-135 Low Gravity Simulation Flight Preparation; (3) In-Line Holographic Microscopy; and (4) Holographic Optical Schlieren System (HOSS). The first task provides for laboratory breadboarding of advanced optical measurement techniques which appear promising for use in Material Processing System (MPS) flight experiments. A laboratory schlieren system has been constructed which simulates a similar optical system on the Fluids Experiment System (FES) which is to be flown on Spacelab 3. The second task allows improved optical systems and breadboards to be built for experiments and hardware tests on the KC-135 aircraft. A new, more stable Mach-Zehnder interferometer has been developed and components have been ordered. The third task is concerned with improvements on the optical system being used to study immiscible fluids. Experiments studying the dynamics of nucleation and the separation of immiscible fluids have been conducted. The four task involves building breadboard reconstruction systems for holograms taken in the HOSS. The HOSS is an early prototype of the Fluids Experiments System (FES) which is scheduled to fly on Spacelab 3.
A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.
A series of copper-nickel alloys were fabricated, notched tensile specimens machined for each alloy, and the specimens tested in 34.5 MPa hydrogen and in air. A notched tensile ratio was determined for each alloy and the hydrogen environment embrittlement (HEE) determined for the alloys of 47.7 weight percent nickel to 73.5 weight percent nickel. Stacking fault probability and stacking fault energies were determined for each alloy using the x ray diffraction line shift and line profiles technique. Hydrogen environment embrittlement was determined to be influenced by stacking fault energies; however, the correlation is believed to be indirect and only partially responsible for the HEE behavior of these alloys.
Up to six different samples processed. Experimental melting and casting furnace designed to perform metallurgical studies in low gravity.
A screening program to determine the effects of high pressure hydrogen on selected candidate materials for advanced single crystal turbine blade applications is examined. The alloys chosen for the investigation are CM SX-2, CM SX-4C, Rene N-4, and PWA1480. Testing is carried out in hydrogen and helium at 34 MPa and room temperature, with both notched and unnotched single crystal specimens. Results show a significant variation in susceptibility to Hydrogen Environment Embrittlement (HEE) among the four alloys and a marked difference in fracture topography between hydrogen and helium environment specimens.
The nickel-base superalloy MAR-246(Hf) was studied to determine the factors affecting basic morphology and fatigue properties. Of particular interest was the degradation of fatigue properties with deviation from the 001 growth orientation. Examination of directionally solidified samples showed a dependence of carbide shape and interdentritic segregation on growth rate. Heat treatment studies focused on the gamma prime structure, determining that it reaches maximum growth after twenty-four hours but its size and stability depends on the temperature of the treatment. Fatigue test specimens were oriented crystallographically in the failed and unfailed regions and found to have rotated their orientation during the testing if they were located a significant distance from 001. This would place increased strain on the crystal and precipitate early failure.
This paper updates a previous paper in this journal on shadowgraph and schlieren studies of gravity related fluid flow during solidification. The research has now been extended to include interferometric data by the use of a Mach-Zehnder interferometer on a NASA KC-135 aircraft flying a parabolic trajectory. It has thus been possible to obtain quantitative temperature and concentration profiles in an ammonium chloride metal-model material being solidified in microgravity. The results indicate that the growth interface is more stable under low-gravity conditions than in a terrestrial environment.
Optical interferometric, shadowgraph, and streak photographic methods are used to obtain temperature profiles, concentration gradients, and fluid velocities in NH4Cl-H2O metal-model solution during unidirectional solidification in microgravity. This study elucidates earlier low gravity suborbital rocket experiments and lays the groundwork for Space Shuttle experiments. The design and operation of the optical units are presented, and results are detailed to ground based experiments. The low gravity experiments were conducted using a KC-135 aircraft flying a parabolic trajectory.
The development of regularly sized and spaced rods or spheres in a monotectic system is presently considered in terms of interface breakdown and capillary instability mechanisms between two liquid phases. The most important relationship, which governs the rod-to-aligned spheres transition, is the temperature gradient-to-growth rate ratio that determines the depth of the intercellular nodes. Rods will develop when these nodes are shallow by comparison to rod circumference, and spheres will develop when they are deep.
Composite materials were directionally solidified using a new technique to align the constituents longitudinally along the length of the specimen. In some instances a tin coating was applied and diffused into the sample to form a high transition temperature superconducting phase. The superconducting properties were measured and compared with the properties obtained for powder composites and re-directionally solidified powder compacts. The samples which were compacted and redirectionally solidified showed the highest transition temperature and wildest transition range. This indicates that both steps, powder compaction and resolidification, determine the final superconducting properties of the material.
Optical interferometric, shadowgraph, and streak photographic methods are used to obtain temperature profiles, concentration gradients, and fluid velocities in NH4Cl-H2O metal-model solution during unidirectional solidification in microgravity. This study elucidates earlier low gravity suborbital rocket experiments and lays the groundwork for space shuttle experiments. The design and operation of the optical units are presented, and results are detailed to ground based experiments. The low gravity experiments were conducted using a KC-135 aircraft flying a parabolic trajectory.
The results of experiments on the tin-15 wt pct lead system are presented, showing the effects on microstructure of solidification in the presence of acceleration forces from 0.0001 to 5 g for three cooling rates. An increase in the acceleration level is shown to drive fluid flow and cause dendrite remelting, fragmentation, and macrosegregation. The cooling rate impacts the final structure through its control of dendrite arm spacings and permeability to fluid flow. At the low (0.0001 g) acceleration, dendrite arm spacings deviated from the predicted relationship to cooling rate. An explanation for this anomaly is given which considers the temperature and concentration gradients in the low-gravity environment.
The tin-15 wt pct lead and tin-3 wt pct bismuth alloys have been solidified in the low-gravity environment provided by the Space Processing Applications Rocket (SPAR), on the KC-135 airplane, and at high 'g' levels in a centrifuge furnace. In each case the resultant cast structure was significantly different from that obtained in ground based experiments. Earlier low-gravity studies with the metal-model system NH4Cl-H2O presaged these results. This paper presents and discusses the influence of changes in the gravity force on the grain structure of these materials.