Engineering topics

Lowell, C. E.

Publications and source records attributed to Lowell, C. E..

At least 19 records

NASA NTRS2000

Cyclic Oxidation Testing and Modelling: A NASA Lewis Perspective

The Materials Division of the NASA Lewis Research Center has been heavily involved in the cyclic oxidation of high temperature materials for 30 years. Cyclic furnace and burner rig apparati have been developed, refined, and replicated to provide a large scale facility capable of evaluating many materials by a standard technique. Material behavior is characterized by weight change data obtained throughout the test, which has been modelled in a step-wise process of scale growth and spallation. This model and a coupled diffusion model have successfully described cyclic behavior for a number of systems and have provided insights regarding life prediction and variations in the spalling process. Performance ranking and mechanistic studies are discussed primarily for superalloys and coating alloys. Similar cyclic oxidation studies have been performed on steels, intermetallic compounds, thermal barrier coatings, ceramics, and ceramic composites. The most common oxidation test was performed in air at temperatures ranging from 800 deg. to 1600 C, for times up to 10000 h, and for cycle durations of 0.1 to 1000 h. Less controlled, but important, test parameters are the cooling temperature and humidity level. Heating and cooling rates are not likely to affect scale spallation. Broad experience has usually allowed for considerable focus and simplification of these test parameters, while still revealing the principal aspects of material behavior and performance. Extensive testing has been performed to statistically model the compositional effects of experimental alloys and to construct a comprehensive database of complex commercial alloys.

Smialek, J. L.↗

NASA NTRS1995

NiAl-Base Composite Containing High Volume Fraction of AIN Particulate for Advanced Engines

Cryomilling of prealloyed NiAl containing 53 at. % AJ was carried out to achieve high nitrogen levels. The consolidation of cryomilled powder by extrusion or hot pressing/ hot isostatic pressing resulted in a fully dense NiAl-base composite containing 30 vol. % of inhomogeneously distributed, nanosized AIN particulate. The NiAl-30AIN composite exhibited the highest compression yield strengths at all temperatures between 300 and 1300 K as compared with other compositions of NiAl-AIN composite. The NiAl-30AIN specimens tested under compressive creep loading between 1300 and 1500 K also exhibited the highest creep resistance with very little surface oxidation indicating also their superior elevated temperature oxidation resistance. In the high stress exponent regime, the strength is proportional to the square root of the AIN content and in the low stress exponent regime, the influence of AIN content on strength appears to be less dramatic. The specific creep strength of this material at 1300 K is superior to a first generation Ni-base single crystal superalloy. The improvements in elevated temperature creep strength and oxidation resistance have been achieved without sacrificing the room temperature fracture toughness of the NiAl-base material. Based on its attractive combination of properties, the NiAl-30AIN composite is a potential candidate for advanced engine applications,

Hebsur, Mohan G.↗

NASA NTRS1990

Computer Simulation Of Cyclic Oxidation

Computer model developed to simulate cyclic oxidation of metals. With relatively few input parameters, kinetics of cyclic oxidation simulated for wide variety of temperatures, durations of cycles, and total numbers of cycles. Program written in BASICA and run on any IBM-compatible microcomputer. Used in variety of ways to aid experimental research. In minutes, effects of duration of cycle and/or number of cycles on oxidation kinetics of material surveyed.

Probst, H. B.↗

NASA NTRS1988

Computer simulation of cyclic oxidation

A computer program has been developed which simulates the cyclic oxidation behavior of materials. The simulation is based on the assumption that the weight fraction of scale that spalls in any thermal cycle is proportional to the amount of scale present on the surface at the beginning of the cycle. The program provides plots as well as tabular data which describe the cyclic oxidation behavior of a given material. Individual input parameters can be selectively altered and the resulting change in cyclic kinetics determined, allowing the user to quickly survey a wide range of cyclic conditions on the kinetics of a given material.

Probst, H. B.↗

NASA NTRS1986

Nickel base coating alloy

Zirconium is added to a Ni-30 Al (beta) intermetallic alloy in the range of 0.05 w/o to 0.25 w/o. This addition is made during melting or by using metal powders. The addition of zirconium improves the cyclic oxidation resistance of the alloys at temperatures above 1100 C.

Barrett, C. A.↗

NASA NTRS1984

High-Temperature Cyclic Oxidation Data, Volume 1

This first in a series of cyclic oxidation handbooks contains specific-weight-change-versus-time data and X-ray diffraction results derived from high-temperature cyclic tests on high-temperature, high-strength nickel-base gamma/gamma' and cobalt-base turbine alloys. Each page of data summarizes a complete test on a given alloy sample.

Barrett, C. A.↗

NASA NTRS1983

Burner rig study of variables involved in hole plugging of air cooled turbine engine vanes

The effects of combustion gas composition, flame temperatures, and cooling air mass flow on the plugging of film cooling holes by a Ca-Fe-P-containing deposit were investigated. The testing was performed on film-cooled vanes exposed to the combustion gases of an atmospheric Mach 0.3 burner rig. The extent of plugging was determined by measurement of the open hole area at the conclusion of the tests as well as continuous monitoring of some of the tests using stop-action photography. In general, as the P content increased, plugging rates also increased. The plugging was reduced by increasing flame temperature and cooling air mass flow rates. At times up to approximately 2 hours little plugging was observed. This apparent incubation period was followed by rapid plugging, reaching in several hours a maximum closure whose value depended on the conditions of the test.

Deadmore, D. L.↗

NASA NTRS1983

Critical research and advanced technology (CRT) support project

A critical technology base for utility and industrial gas turbines by planning the use of coal-derived fuels was studied. Development tasks were included in the following areas: (1) Combustion - investigate the combustion of coal-derived fuels and methods to minimize the conversion of fuel-bound nitrogen to NOx; (2) materials - understand and minimize hot corrosion; (3) system studies - integrate and focus the technological efforts. A literature survey of coal-derived fuels was completed and a NOx emissions model was developed. Flametube tests of a two-stage (rich-lean) combustor defined optimum equivalence ratios for minimizing NOx emissions. Sector combustor tests demonstrated variable air control to optimize equivalence ratios over a wide load range and steam cooling of the primary zone liner. The catalytic combustion of coal-derived fuels was demonstrated. The combustion of coal-derived gases is very promising. A hot-corrosion life prediction model was formulated and verified with laboratory testing of doped fuels. Fuel additives to control sulfur corrosion were studied. The intermittent application of barium proved effective. Advanced thermal barrier coatings were developed and tested. Coating failure modes were identified and new material formulations and fabrication parameters were specified. System studies in support of the thermal barrier coating development were accomplished.

Furman, E. R.↗

NASA NTRS1983

Cyclic oxidation of superalloys

The development of mathematical/computer models of cyclic oxidation in high-temperature alloys is described. The acceleration of oxidation attack caused by the spalling of protective oxide scales is discussed. The COREST paralinear model based on empirical data, designed by Barrett and Pressler, is found to be of limited value. Basic research on the spalling process in different alloy systems is reviewed, and the phenomenon is characterized: occurring mainly within the oxide, it is caused by the different thermal expansion coefficients of oxide and metal and is a linear function of the total retained oxide. This information has been used in the development of the discrete oxide-spall model COSP and in its modification by addition of a diffusion-zone-profile model to predict the failure of components (Heckel and Nesbitt, unpublished). The COSP model is shown to produce good predictions of cyclic oxidation under a variety of conditions, using data from simple isothermic tests.

Lowell, C. E.↗

NASA NTRS1982

Wire EDM for Refractory Materials

In an attempt to reduce fabrication time and costs, Wire Electrical Discharge Machine (Wire EDM) method was investigated as tool for fabricating matched blade roots and disk slots. Eight high-strength nickel-base superalloys were used. Computer-controlled Wire EDM technique provided high quality surfaces with excellent dimensional tolerances. Wire EDM method offers potential for substantial reductions in fabrication costs for "hard to machine" alloys and electrically conductive materials in specific high-precision applications.

Zellars, G. R.↗

NASA NTRS1982

Nicral ternary alloy having improved cyclic oxidation resistance

NiCrAl alloys are improved by the addition of zirconium. These alloys are in the Beta or gamma/gamma' + Beta region of the ternary system. Zirconium is added in a very low amount between 0.06 and 0.20 weight percent. There is a narrow optimum zirconium level at the low value of 0.13 weight percent. Maximum resistance to cyclic oxidation is achieved when the zirconium addition is at the optimum value.

Barrett, C. A.↗

NASA NTRS1982

Gas turbine critical research and advanced technology (CRT) support project

The technical progress to provide a critical technology base for utility gas turbine systems capable of burning coal-derived fuels is summarized. Project tasks include the following: (1) combustion - to investigate the combustion of coal-derived fuels and the conversion of fuel-bound nitrogen to NOx; (2) materials - to understand and prevent the hot corrosion of turbine hot section materials; and (3) system studies - to integrate and guide the technological efforts. Technical accomplishments include: an extension of flame tube combustion testing of propane - Toluene Fuel Mixtures to vary H2 content from 9 to 18 percent by weight and the comparison of results with that predicted from a NASA Lewis General Chemical Kinetics Computer Code; the design and fabrication of combustor sector test section to test current and advanced combustor concepts; Testing of Catalytic combustors with residual and coal-derived liquid fuels; testing of high strength super alloys to evaluate their resistance to potential fuel impurities using doped clean fuels and coal-derived liquids; and the testing and evaluation of thermal barrier coatings and bond coatings on conventional turbine materials.

Furman, E. R.↗

NASA NTRS1982

Long-term high-velocity oxidation and hot corrosion testing of several NiCrAl and FeCrAl base oxide dispersion strengthened alloys

Several oxide dispersion strengthened (ODS) alloys have been tested for cyclic, long-term, high gas-velocity resistance to oxidation at 1100 C and hot corrosion at 900 C. Both nominally Ni-16Cr-4Al and Fe-20Cr-4.5Al ODS alloys were subjected up to about 2500 cycles, where each cycle consisted of 1 hr in a hot, Mach 0.3 combusted gas stream followed by a 3-min quench in an ambient temperature, Mach 0.3 air blast. For comparison to existing technology, a coated superalloy was simultaneously tested. The ODS iron alloy exhibited clearly superior behavior, surviving 3800 oxidation and 2300 hot corrosion cycles essentially unscathed. While the ODS nickel alloys exhibited adequate oxidation resistance, the long-term hot corrosion resistance could be marginal, since the best life for such alloys under these conditions was only about 1100 cycles. However, the hot corrosion resistance of the ODS Ni-base alloys is excellent in comparison to that of traditional superalloys.

Lowell, C. E.↗

NASA NTRS1982

Failure mechanisms of thermal barrier coatings exposed to elevated temperatures

The failure of a ZrO2-8%Y2O3/Ni-14% Al-0.1% Zr coating system on Rene 41 in Mach 0.3 burner rig tests was characterized. High flame and metal temperatures were employed in order to accelerate coating failure. Failure by delamination was shown to precede surface cracking or spalling. This type of failure could be duplicated by cooling down the specimen after a single long duration isothermal high temperature cycle in a burner rig or a furnace, but only if the atmosphere was oxidizing. Stresses due to thermal expansion mismatch on cooling coupled with the effects of plastic deformation of the bond coat and oxidation of the irregular bond coat are the probable life limiting factors. Heat up stresses alone could not fail the coating in the burner rig tests. Spalling eventually occurs on heat up but only after the coating has already failed through delamination.

Miller, R. A.↗

NASA NTRS1981

High temperature alkali corrosion in high velocity gases

The effects of potential impurities in coal derived liquids such as Na, K, Mg, Ca and Cl on the accelerated corrosion of IN-100, U-700, IN-792 and Mar-M509 were investigated using a Mach 0.3 burner rig for times to 1000 hours in one hour cycles. These impurities were injected in combination as aqueous solutions into the combustor of the burner rig. The experimental matrix utilized was designed statistically. The extent of corrosion was determined by metal recession. The metal recession data were fitted by linear regression to a polynomial expression which allows both interpolation and extrapolation of the data. As anticipated, corrosion increased rapidly with Na and K, and a marked maximum in the temperature response was noted for many conditions. In contrast, corrosion decreased somewhat as the Ca, Mg and Cl contents increased. Extensive corrosion was observed at concentrations of Na and K as low as 0.1 PPM at long times.

Lowell, C. E.↗

NASA NTRS1981

High temperature cyclic oxidation furnace testing at NASA Lewis Research Center

A standardized method of testing the cyclic oxidation resistance of various alloys in static air up to 1200 C has been developed and routinely used at the NASA Lewis Research Center. Test samples are automatically raised and lowered into a resistance wound furnace for a series of fixed-interval heating and cooling cycles. Spall catchers collect the accumulated spall from each sample. The samples are weighed intermittently to generate specific weight change with time data. At various test times the samples and the accumulated spall are analyzed by X-ray diffraction. A computer program is used to print out the specific weight change versus time data and the X-ray data in tabular form and to plot the specific weight change versus time data in a publishable format. The data are also organized and indexed. So far several hundred Fe-, Ni-, and Co-base alloys have been tested using this basic procedure and will form the basis of a series of cyclic oxidation handbooks to be published by NASA. Such specific weight change/time data have been used to estimate the oxidative metal consumption by several computer modeling techniques both to rank alloys and to estimate life.

Barrett, C. A.↗

NASA NTRS1981

Gas-turbine critical research and advanced technology support project

A technology data base for utility gas turbine systems capable of burning coal derived fuels was developed. The following areas are investigated: combustion; materials; and system studies. A two stage test rig is designed to study the conversion of fuel bound nitrogen to NOx. The feasibility of using heavy fuels in catalytic combustors is evaluated. A statistically designed series of hot corrosion burner rig tests was conducted to measure the corrosion rates of typical gas turbine alloys with several fuel contaminants. Fuel additives and several advanced thermal barrier coatings are tested. Thermal barrier coatings used in conjunction with low critical alloys and those used in a combined cycle system in which the stack temperature was maintained above the acid corrosion temperature are also studied.

Clark, J. S.↗

NASA NTRS1981

The effects of trace impurities in coal-derived liquid fuels on deposition and accelerated high temperature corrosion of cast superalloys

The effects of trace metal impurities in coal-derived liquids on deposition, high temperature corrosion and fouling were examined. Alloys were burner rig tested from 800 to 1100 C and corrosion was evaluated as a function of potential impurities. Actual and doped fuel test were used to define an empirical life prediction equation. An evaluation of inhibitors to reduce or eliminate accelerated corrosion was made. Barium and strontium were found to limit attack. Intermittent application of the inhibitors or silicon additions were found to be effective techniques for controlling deposition without losing the inhibitor benefits. A computer program was used to predict the dew points and compositions of deposits. These predictions were confirmed in deposition test. The potential for such deposits to plug cooling holes of turbine airfoils was evaluated. Tests indicated that, while a potential problem exists, it strongly depended on minor impurity variations.

Lowell, C. E.↗