Engineering topics

Locci, Ivan E.

Publications and source records attributed to Locci, Ivan E..

30 records · Page 2

NASA NTRS2002

Effects of Microalloying on the Microstructures and Mechanical Properties of Directionally Solidified Ni-33(at.%)Al-31Cr-3Mo Eutectic Alloys Investigated

Despite nickel aluminide (NiAl) alloys' attractive combination of oxidation and thermophysical properties, their development as replacements for superalloy airfoils in gas turbine engines has been largely limited by difficulties in developing alloys with an optimum combination of elevated-temperature creep resistance and room-temperature fracture toughness. Alternatively, research has focused on developing directionally solidified NiAl-based in situ eutectic composites composed of NiAl and (Cr,Mo) phases in order to obtain a desirable combination of properties a systematic investigation was undertaken at the NASA Glenn Research Center to examine the effects of small additions of 11 alloying elements (Co, Cu, Fe, Hf, Mn, Nb, Re, Si, Ta, Ti, and Zr) in amounts varying from 0.25 to 1.0 at.% on the elevated-temperature strength and room-temperature fracture toughness of directionally solidified Ni-33Al-31Cr-3Mo eutectic alloy. The alloys were grown at 12.7 mm/hr, where the unalloyed eutectic base alloy exhibited a planar eutectic microstructure. The different microstructures that formed because of these fifth-element additions are included in the table. The additions of these elements even in small amounts resulted in the formation of cellular microstructures, and in some cases, dendrites and third phases were observed. Most of these elemental additions did not improve either the elevated-temperature strength or the room-temperature fracture toughness over that of the base alloy. However, small improvements in the compression strength were observed between 1200 and 1400 K when 0.5 at.% Hf and 0.25 at.% Ti were added to the base alloy. The results of this study suggest that the microalloying of Ni-33Al-31Cr-3Mo will not significantly improve either its elevatedtemperature strength or its room-temperature fracture toughness. Thus, any improvements in these properties must be acquired by changing the processing conditions.

Whittenberger, J. Daniel↗

NASA NTRS2000

Very Long Term Oxidation of Titanium Aluminides Investigated

Titanium aluminides (TiAl) are of great interest for intermediate-temperature (600 to 850 C) aerospace and power-generation applications because they offer significant weight savings over today's nickel alloys. TiAl alloys are being investigated for low-pressure turbine blade applications, exhaust nozzle components, and compressor cases in advanced subsonic and supersonic engines. Significant progress has been made in understanding the fundamental aspects of the oxidation behavior of binary TiAl alloys. However, most of this work has concentrated on short term (<1000 hr), high-temperature (900 to 1000 C) exposures. Also, there is not much data available in the literature regarding the oxidation behavior of the quaternary and higher order engineering alloys. This is especially true for the very long term, low-temperature conditions likely to be experienced during aerospace applications. An investigation at the NASA Glenn Research Center at Lewis Field was undertaken to characterize the long-term oxidation behavior of various model and advanced titanium aluminides for periods up to 7000 hr at 704 C in air using a high-resolution field emission scanning electron microscope. Also, a unique surface treatment technique developed to improve the oxidation resistance of TiAl was evaluated. The alloys included in this investigation are listed in the table. The table also shows typical alloy compositions and the specific weight changes and scale thickness measured for each alloy after exposure to 700 C for 7000 hr in air.

Locci, Ivan E.↗

NASA NTRS2000

Directionally Solidified NiAl-Based Alloys Studied for Improved Elevated-Temperature Strength and Room-Temperature Fracture Toughness

Efforts are underway to replace superalloys used in the hot sections of gas turbine engines with materials possessing better mechanical and physical properties. Alloys based on the intermetallic NiAl have demonstrated potential; however, they generally suffer from low fracture resistance (toughness) at room temperature and from poor strength at elevated temperatures. Directional solidification of NiAl alloyed with both Cr and Mo has yielded materials with useful toughness and elevated-temperature strength values. The intermetallic alloy NiAl has been proposed as an advanced material to extend the maximum operational temperature of gas turbine engines by several hundred degrees centigrade. This intermetallic alloy displays a lower density (approximately 30-percent less) and a higher thermal conductivity (4 to 8 times greater) than conventional superalloys as well as good high-temperature oxidation resistance. Unfortunately, unalloyed NiAl has poor elevated temperature strength (approximately 50 MPa at 1027 C) and low room-temperature fracture toughness (about 5 MPa). Directionally solidified NiAl eutectic alloys are known to possess a combination of high elevated-temperature strength and good room-temperature fracture toughness. Research has demonstrated that a NiAl matrix containing a uniform distribution of very thin Cr plates alloyed with Mo possessed both increased fracture toughness and elevated-temperature creep strength. Although attractive properties were obtained, these alloys were formed at low growth rates (greater than 19 mm/hr), which are considered to be economically unviable. Hence, an investigation was warranted of the strength and toughness behavior of NiAl-(Cr,Mo) directionally solidified at faster growth rates. If the mechanical properties did not deteriorate with increased growth rates, directional solidification could offer an economical means to produce NiAl-based alloys commercially for gas turbine engines. An investigation at the NASA Glenn Research Center at Lewis Field was undertaken to study the effect of the directional solidification growth rate on the microstructure, room temperature fracture toughness, and strength at 1027 C of a Ni-33Al-31Cr-3Mo eutectic alloy. The directionally solidified rates varied between 7.6 and 508 millimeters per hour Essentially fault-free, alternating (Cr, Mo)/NiAl lamellar plate microstructures (left photograph) were formed during growth at and below 12.7 mm/hr, whereas cellular microstructures (right photograph) with the (Cr, Mo) phase in a radial spokelike pattern were developed at faster growth rates. The compressive strength at 1027 C continuously increased with increasing growth rate and did not indicate a maxima as was reported for directionally solidified Ni-33Al-34Cr. Surprisingly, samples with the lamellar plate microstructure (left photograph) possessed a room-temperature fracture toughness of approximately 12 MPa(sup square root of m), whereas all the alloys with a cellular microstructure had a toughness of about 17 MPa(sup square root of m). These results are significant since they clearly demonstrate that Ni-33Al-31Cr-3Mo can be directionally solidified at much faster growth rates without any observable deterioration in its mechanical properties. Thus, the potential to produce strong, tough NiAl-based eutectics at commercially acceptable growth rates exists. Additional testing and alloy optimization studies are underway.

Whittenberger, J. Daniel↗

NASA NTRS2000

Creep Properties of NiAl-1Hf Single Crystals Re-Investigated

NiAl-1Hf single crystals have been shown to be quite strong at 1027 C, with strength levels approaching those of advanced Ni-based superalloys. Initial testing, however, indicated that the properties might not be reproducible. Study of the 1027 C creep behavior of four different NiAl-1Hf single-crystal ingots subjected to several different heat treatments indicated that strength lies in a narrow band. Thus, we concluded that the mechanical properties are reproducible. Recent investigations of the intermetallic NiAl have confirmed that minor alloying additions combined with single-crystal growth technology can produce elevated temperature strength levels approaching those of Ni-based superalloys. For example, General Electric alloy AFN 12 {Ni-48.5(at.%) Al-0.5Hf-1Ti-0.05Ga} has a creep rupture strength equivalent to Rene 80 combined with a approximately 30-percent lower density, a fourfold improvement in thermal conductivity, and the ability to form a self-protective alumina scale in aggressive environments. Although the compositions of strong NiAl single crystals are relatively simple, the microstructures are complex and vary with the heat treatment and with small ingot-toingot variations in the alloy chemistry. In addition, initial testing suggested a strong dependence between microstructure and creep strength. If these observations were true, the ability to utilize NiAl single-crystal rotating components in turbine machinery could be severely limited. To investigate the possible limitations in the creep response of high-strength NiAl single crystals, the NASA Glenn Research Center at Lewis Field initiated an in depth investigation of the effect of heat treatment on the microstructure and subsequent 1027 C creep behavior of [001]-oriented NiAl-1Hf with a nominal chemistry of Ni-47.5Al-1Hf-0.5Si. This alloy was selected since four ingots, grown over a number of years and possessing slightly different compositions, were available for study. Specimens taken from the ingots were subjected to several heat treatment schedules, examined by transmission electron microscopy, and tested in both compression and tension. An example of the microstructure found in a [001]-oriented NiAl-1Hf specimen after a solution treatment at 1317 C for 50 hr followed by air cooling is illustrated in the image on the left, where the NiAl matrix contains a uniform distribution of nanometer-scale Gphase (Ni16Hf6Si7) precipitates. Other heat treating schedules produced microstructures with nanometer-sized G-phase cubes and plates or, in an extreme case, produced a microstructure with all the G-phase converted to Heusler (Ni2AlHf) particles. The results of 1027 C creep strength and strain rate testing are illustrated which summarizes data from tensile and compressive testing of samples cut from all four NiAl-1Hf ingots and subjected to a variety of heat treatment schedules. With one exception, all the strength values lie in a narrow band that spans six orders of magnitude in strain rate. The only factor that produced results outside of this band was the heat treatment schedule that dissolved all the G-phase and replaced it with Heusler precipitates. The results portrayed in this figure lead to the important practical conclusion that the elevated-temperature creep properties of NiAl-1Hf single crystals are reproducible and are not affected by small variations in alloy chemistry from ingot to ingot or by different initial distributions of G-phase in the heat-treated alloy. The only variable in this study that produced a significant and delerious effect on mechanical strength was a post-solution heat treatment that lead to the complete disappearance of the G-phase in favor of Heusler precipitates.

Whittenberger, J. Daniel↗

NASA NTRS2000

1300 K Compressive Properties of Directionally Solidified Ni-33Al-33Cr-1Mo

The Ni-33Al-33Cr-1Mo eutectic has been directionally solidified by a modified Bridgeman technique at growth rates ranging from 7.6 to 508 mm/h to produce grain/cellular microstructures, containing alternating plates of NiAl and Cr alloyed with Mo. The grains had sharp boundaries for slower growth rates (< 12.7 mm/h), while faster growth rates (> 25.4 mm/h) lead to cells bounded by intercellular regions. Compressive testing at 1300 K indicated that alloys DS'ed at rates between 25.4 to 254 mm/h possessed the best strengths which exceed that for the as-cast alloy.

Whittenberger, J. Daniel↗

NASA NTRS1999

Monolithic Cu-Cr-Nb Alloys for High Temperature, High Heat Flux Applications

Work during the prior four years of this grant has resulted in significant advances in the development of Cu-8 Cr4 Nb and related Cu-Cr-Nb alloys. The alloys are nearing commercial use in the Reusable Launch Vehicle (RLV) where they are candidate materials for the thrust cell liners of the aerospike engines being developed by Rocketdyne. During the fifth and final year of the grant, it is proposed to complete development of the design level database of mechanical and thermophysical properties and transfer it to NASA Glenn Research Center and Rocketdyne. The database development work will be divided into three main areas: Thermophysical Database Augmentation, Mechanical Testing and Metallography and Fractography. In addition to the database development, work will continue that is focussed on the production of alternatives to the powder metallurgy alloys currently used. Exploration of alternative alloys will be aimed at both the development of lower cost materials and higher performance materials. A key element of this effort will be the use of Thermo-Calc software to survey the solubility behavior of a wide range of alloying elements in a copper matrix. The ultimate goals would be to define suitable alloy compositions and processing routes to produce thin sheets of the material at either a lower cost, or, with improved mechanical and thermal properties compared to the current Cu-Cr-Nb powder metallurgy alloys.

Ellis, David L.↗

NASA NTRS1996

The Oxidation and Protection of Gamma Titanium Aluminides

The excellent density-specific properties of the gamma class of titanium aluminides make them attractive for intermediate-temperature (600-850 C) aerospace applications. The oxidation and embrittlement resistance of these alloys is superior to that of the alpha(sub 2) and orthorhombic classes of titanium aluminides. However, since gamma alloys form an intermixed Al2O3/TiO2 scale in air rather than the desired continuous Al2O3 scale, oxidation resistance is inadequate at the high end of this temperature range (i.e., greater than 750-800 C). For applications at such temperatures, an oxidation-resistant coating will be needed; however, a major drawback of the oxidation-resistant coatings currently available is severe degradation in fatigue life by the coating. A new class of oxidation-resistant coatings based in the Ti-Al-Cr system offers the potential for improved fatigue life.

Brady, Michael P.↗

NASA NTRS1992

Influence of Processing on the Microstructure and Mechanical Properties of a NbAl3-Base Alloy

Induction melting and rapid solidification processing, followed by grinding to 75-micron powder and P/M consolidation, have been used to produce a multiphase, NbAl3-based, oxidation-resistant alloy of Nb-67Al-7Cr-0.5Y-0.25W composition whose strength and ductility are significantly higher than those of the induction-melted alloy at test temperatures of up to 1200 K. Attention is given to the beneficial role of microstructural refinement; the major second phase, AlNbCr, improves both oxidation resistance and mechanical properties.

Hebsur, Mohan G.↗

NASA NTRS1990

Making Fiber-Reinforced Metal By Rapid Solidification

Report highlights advantages and versatility of rapid-solidification technology in fabrication of fiber-reinforced metal-matrix composites. Discusses present role and future potential of technology. Describes variety of methods for making monotape. Common to all is rapid solidification of liquid metal - "rapid" meaning cooling rates of 10 to 4th power to 10 to 6th power K/s. Also includes tables that compare rapid-solidification methods and provides extensive list of references.

Noebe, Ronald D.↗

NASA NTRS1989

The role of rapid solidification processing in the fabrication of fiber reinforced metal matrix composites

Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed.

Locci, Ivan E.↗

NASA NTRS1988

Microstructures in rapidly solidified niobium aluminides

The microstructures of niobium aluminides produced by chill block melt spinning were compared to those of niobium aluminides produced by conventional casting. The rapidly solidified alloys were rapidly solidified by melt spinning in an argon atmosphere, and the melt-spun ribbons were examined by optical, X-ray, and TEM techniques. Microstructures were found to range from single-phase for Nb-75 at. pct Al (NbAl3) to two phase for Nb-46 at. pct Al (NbAl3 + Nb2Al). It was found that the melt spinning of Nb-aluminides produced finer grained microstructures than those produced in induction-melted ingots or in powders produced by the rotating electrode process. Ternary additions such as Cr, Ti, and Si tended to form intermetallic phases along the grain boundaries.

Hebsur, Mohan G.↗

NASA NTRS1988

Rapid solidification research at the NASA Lewis Research Center

This paper describes the research program initiated at the NASA Lewis Research Center for the study of rapid solidification of high temperature materials, with the major purpose for the development of advanced high-temperature and heat-flux materials for aircraft and aerosphace applications. Particular attention is given to the development of three alloys: Ni-aluminides, Nb-alloys, and Cu-alloys. Rapid solidification processing yielded alloys with novel microstructures, very fine grain sizes, reduced chemical segregation, and metastable extended solid solutions.

Locci, Ivan E.↗