Engineering topics

Nathal, M. V.

Publications and source records attributed to Nathal, M. V..

At least 19 records

NASA NTRS2004

Superalloy Lattice Block Structures

Initial investigations of investment cast superalloy lattice block suggest that this technology will yield a low cost approach to utilize the high temperature strength and environmental resistance of superalloys in lightweight, damage tolerant structural configurations. Work to date has demonstrated that relatively large superalloy lattice block panels can be successfully investment cast from both IN-718 and Mar-M247. These castings exhibited mechanical properties consistent with the strength of the same superalloys measured from more conventional castings. The lattice block structure also accommodates significant deformation without failure, and is defect tolerant in fatigue. The potential of lattice block structures opens new opportunities for the use of superalloys in future generations of aircraft applications that demand strength and environmental resistance at elevated temperatures along with low weight.

Nathal, M. V.↗

NASA NTRS2003

Superalloy Lattice Block Structures

In their simplest form, lattice block panels are produced by direct casting and result in lightweight, fully triangulated truss-like configurations which provide strength and stiffness [2]. The earliest realizations of lattice block were made from A1 and steels, primarily under funding from the US Navy [3]. This work also showed that the mechanical efficiency (eg., specific stiffness) of lattice block structures approached that of honeycomb structures [2]. The lattice architectures are also less anisotropic, and the investment casting route should provide a large advantage in cost and temperature capability over honeycombs which are limited to alloys that can be processed into foils. Based on this early work, a program was initiated to determine the feasibility of extending the high temperature superalloy lattice block [3]. The objective of this effort was to provide an alternative to intermetallics and composites in achieving a lightweight high temperature structure without sacrificing the damage tolerance and moderate cost inherent in superalloys. To establish the feasibility of the superalloy lattice block concept, work was performed in conjunction with JAMCORP, Inc. Billerica, MA, to produce a number of lattice block panels from both IN71 8 and Mar-M247.

Whittenberger, J. D.↗

NASA NTRS2003

High Conductivity Materials for High Heat Flux Applications in Space Propulsion Systems

GRCop-84 is a new copper base alloy with an excellent combination of strength and conductivity and has been developed to the point that it is a strong candidate for near term rocket engine applications. This work sought to establish the feasibility of new alloys with capabilities beyond GRCop-84. The use of coatings as environmental and thermal barriers adds further capability into the Copper base structure. Finally, Nickel-Aluminum based systems have also been explored.

Nathal, M. V.↗

NASA NTRS2002

Thermocouple Calibration and Accuracy in a Materials Testing Laboratory

A consolidation of information has been provided that can be used to define procedures for enhancing and maintaining accuracy in temperature measurements in materials testing laboratories. These studies were restricted to type R and K thermocouples (TCs) tested in air. Thermocouple accuracies, as influenced by calibration methods, thermocouple stability, and manufacturer's tolerances were all quantified in terms of statistical confidence intervals. By calibrating specific TCs the benefits in accuracy can be as great as 6 C or 5X better compared to relying on manufacturer's tolerances. The results emphasize strict reliance on the defined testing protocol and on the need to establish recalibration frequencies in order to maintain these levels of accuracy.

Lerch, B. A.↗

NASA NTRS2001

Effect of Impact Damage on the Fatigue Response of TiAl Alloy-ABB-2

The ability of gamma-TiAl to withstand potential foreign or domestic object damage is a technical risk to the implementation of gamma-TiAl in low pressure turbine (LPT) blade applications. In the present study, the impact resistance of TiAl alloy ABB-2 was determined and compared to the impact resistance of Ti(48)Al(2)Nb(2)Cr. Specimens were impacted with four different impact conditions with impact energies ranging from 0.22 to 6.09 J. After impacting, the impact damage was characterized by crack lengths on both the front and backside of the impact. Due to the flat nature of gamma-TiAl's S-N (stress vs. cycles to failure) curve, step fatigue tests were used to determine the fatigue strength after impacting. Impact damage increased with increasing impact energy and led to a reduction in the fatigue strength of the alloy. For similar crack lengths, the fatigue strength of impacted ABB-2 was similar to the fatigue strength of impacted Ti(48)Al(2)Nb(2)Cr, even though the tensile properties of the two alloys are significantly different. Similar to Ti(48)Al(2)Nb(2)Cr, ABB-2 showed a classical mean stress dependence on fatigue strength. The fatigue strength of impacted ABB-2 could be accurately predicted using a threshold analysis.

Draper, S. L.↗

NASA NTRS2000

The Effect of Ballistic Impacts on the High Cycle Fatigue Properties of Ti-48Al-2Nb-2Cr (at.%)

The ability of gamma - TiAl to withstand potential foreign and/or domestic object damage is a technical risk to the implementation of gamma - TiAl in low pressure turbine (LPT) blade applications. The overall purpose of the present study was to determine the influence of ballistic impact damage on the high cycle fatigue strength of gamma - TiAl simulated LPT blades. Impact and specimen variables included ballistic impact energy, projectile hardness, impact temperature, impact location, and leading edge thickness. The level of damage induced by the ballistic impacting was studied and quantified on both the impact (front) and backside of the specimens. Multiple linear regression was used to model the cracking and fatigue response as a function of the impact variables. Of the impact variables studied, impact energy had the largest influence on the response of gamma - TiAl to ballistic impacting. Backside crack length was the best predictor of remnant fatigue strength for low energy impacts (<0.74J) whereas Hertzian crack length (impact side damage) was the best predictor for higher energy impacts. The impacted gamma - TiAl samples displayed a classical mean stress dependence on the fatigue strength. For the fatigue design stresses of a 6th stage LPT blade in a GE90 engine, a Ti-48Al-2Nb-2Cr LPT blade would survive an impact of normal service conditions.

Draper, S. L.↗

NASA NTRS1997

Strong, Tough, and Pest Resistant MoSi2-Base Hybrid Composite for Structural Applications

Addition of about 30 to 50 vol % of Si3N4 particulate to MoSi2 improved resistance to low temperature accelerated oxidation by forming a Si2ON2 protective scale and thereby eliminating catastrophic 'pest failure'. The Si3N4 addition also improved the high temperature creep strength by nearly five orders of magnitude, doubled the room temperature toughness and significantly lowered the CTE of the MoSi2 and eliminated matrix cracking in SCS-6 reinforced composites even after thermal cycling. The SCS-6 fiber reinforcement improved the room temperature fracture toughness by seven times and impact resistance by five times. The composite exhibited excellent strength and toughness improvement up to 1400 C. More recently, tape casting was adopted as the preferred processing of MoSi2-base composites for improved fiber spacing, ability to use small diameter fibers, and for lower cost. Good strength and toughness values were also obtained with fine diameter Hi-Nicalon tow fibers. This hybrid composite remains competitive with ceramic matrix composites as a replacement for Ni-base superalloys in aircraft engine applications.

Hebsur, M. G.↗

NASA NTRS1996

Microstructure and Phase Stability of Single Crystal NiAl Alloyed with Hf and Zr

Six near stoichiometric, NiAl single-crystal alloys, with 0.05-1.5 at.% of Hf and Zr additions plus Si impurities, were microstructurally analyzed in the as-cast, homogenized, and aged conditions. Hafnium-rich interdendritic regions, containing the Heusler phase (Ni2AlHf), were found in all the as-cast alloys containing Hf. Homogenization heat treatments partially reduced these interdendritic segregated regions. Transmission electron microscopy (TEM) observations of the as-cast and homogenized microstructures revealed the presence of a high density of fine Hf (or Zr) and Si-rich precipitates. These were identified as G-phase, Nil6X6Si7, or as an orthorhombic NiXSi phase, where X is Hf or Zr. Under these conditions the expected Heusler phase (beta') was almost completely absent. The Si responsible for the formation of the G and NiHfSi phases is the result of molten metal reacting with the Si-containing crucible used during the casting process. Varying the cooling rates after homogenization resulted in the refinement or complete suppression of the G and NiHfSi phases. In some of the alloys studied, long-term aging heat treatments resulted in the formation of Heusler precipitates, which were more stable at the aging temperature and coarsened at the expense of the G-phase. In other alloys, long-term aging resulted in the formation of the NiXSi phase. The stability of the Heusler or NiXSi phases can be traced to the reactive element (Hf or Zr) to silicon ratio. If the ratio is high, then the Heusler phase appears stable after long time aging. If the ratio is low, then the NiHfSi phase appears to be the stable phase.

Locci, I. E.↗

NASA NTRS1995

High temperature composites

The purpose of this paper is to review the current state of the development of new composite materials for advanced aircraft engines. The advantages and disadvantages of Ti-base, NiAl-base, and MoSi2-base composites as replacements for today's Ni-base superalloys are discussed from the standpoint of key technical issues, current status, and future directions. Results describing progress in both improved understanding of the mechanisms of deformation and fracture, and improved material performance will be covered.

Nathal, M. V.↗

NASA NTRS1993

Physical and mechanical properties of the B2 compound NiAl

Considerable work has been performed on NiAl over the last three decades, with an extremely rapid growth in research on this intermetallic occurring in the last few years due to recent interest in this material for electronic and high temperature structural applications. However, many physical properties and the controlling fracture and deformation mechanisms over certain temperature regimes are still in question. Part of this problem lies in the incomplete characterization of many of the alloys previously investigated. Fragmentary data on processing conditions, chemistry, microstructure and the apparent difficulty in accurately measuring composition has made direct comparison between individual studies sometimes tenuous. Therefore, the purpose of this review is to summarize all available mechanical and pertinent physical properties on NiAl, stressing the most recent investigations, in an attempt to understand the behavior of NiAl and its alloys over a broad temperature range.

Noebe, R. D.↗

NASA NTRS1992

The effect of temperature on the deformation and fracture of SiC/Ti-24Al-11Nb

The effect of temperature on the stress-strain behavior in air and the failure mechanisms of Ti-24Al-11Nb alloy and of a SiC/Ti-24Al-11Nb composite with continuous SiC fibers oriented parallel to the loading direction was investigated over temperature range 23-815 C. It was found that the tensile failure process of SiC/Ti-24Al-11Nb was controlled at all temperatures by fiber fracture. Composite failure occurred at 0.8 percent strain at all temperatures. Debond and frictional stresses at the fiber-matrix interface decreased with increased temperature.

Brindley, P. K.↗

NASA NTRS1992

Creep deformation of B2 aluminides

The creep resistance and elevated temperature deformation mechanisms in CoAl, FeAl, and NiAl are reviewed. The stress and temperature dependencies of the steady state creep rate, the primary creep behavior, the dislocation substructure, and the response during transient tests are used as the main indicators of the deformation processes. In single phase intermetallics, the influence of grain size, stoichiometry, and solid solution hardening have been examined. In addition, the effect of adding dispersoids, precipitates, and other types of reinforcements to improve creep strength are compared.

Nathal, M. V.↗

NASA NTRS1991

Slow strain rate 1200-1400 K compressive properties of NiAl-1Hf

Compression tests are conducted on NiAl-1Hf to assess the elevated-temperature creep behavior of this precipitation-hardened aluminide. While the strength is high under fast strain rates (more than 10 exp -5/s), under slower conditions the alloy is weak. Thus, it is unlikely that effective creep resistance can be obtained in NiAl through small Hf additions.

Whittenberger, J. D.↗

NASA NTRS1991

Creep Deformation of B2 Alumindes

Nathal, M. V.↗

NASA NTRS1991

Microstructure and mechanical properties of a single crystal NiAl alloy with Zr or Hf rich G-phase precipitates

The possibility of producing NiAl reinforced with the G-phase (Ni16X6Si7), where X is Zr or Hf, has been investigated. The microstructure of these NiAl alloys have been characterized in the as-cast and annealed conditions. The G-phases are present as fine cuboidal precipitates (10 to 40 nm) and have lattice parameters almost four times that of NiAl. They are coherent with the matrix and fairly resistant to coarsening during annealing heat treatments. Segregation and nonuniform precipitate distribution observed in as-cast materials were eliminated by homogenization at temperatures near 1600 K. Slow cooling from these temperatures resulted in large plate shaped precipitates, denuded zones, and a loss of coherency in some of the large particles. Faster cooling produced a homogeneous fine distribution of cuboidal G-phase particles in the matrix. Preliminary mechanical properties for the Zr-doped alloy are presented and compared to binary single crystal NiAl. The presence of these precipitates appears to have an important strengthening effect at temperatures not less than 1000 K compared to binary NiAl single crystals.

Locci, I. E.↗

NASA NTRS1991

Effect of Fiber Strength on the Room Temperature Tensile Properties of Sic/Ti-24Al-11Nb

SCA-6 SiC fibers of known strength were incorporated into SiC/Ti-24Al-11Nb (at. percent) composites and the effect of fiber strength variability on room temperature composite strength was investigated. Fiber was etched out of a composite fabricated by the powder cloth technique and the effect of the fabrication process on fiber strength was assessed. The strength of the composite was directly correlated with the strength of the as-received fiber. The strength of composite plates containing mixed fiber strengths was dominated by the lower strength fiber. Fabrication by the powder cloth technique resulted in only a slight degradation of fiber strength. The strength of the composite was found to be overestimated by the rule of mixtures strength calculation. Examination of failed tensile specimens revealed periodic fiber cracks and the failure mode was concluded to be cumulative. With the variation in fiber strength eliminated, the composite UTS was found to have a positive correlation with volume fraction of fiber.

Draper, S. L.↗

NASA NTRS1990

Compatibility of Fe-40Al with various fibers

Chemical reaction can occur at the fiber/matrix interface of intermetallic matrix composites, leading to a degradation of mechanical properties. Fe-40Al matrix composites were fabricated using SiC, B, W, Mo-base, and Al2O3 fibers. Composite samples were heat treated up to 1500 K to study the reaction kinetics, and reaction rates were determined from reaction zone thickness measurements. The Al2O3 and W fibers were found to be compatible with the Fe-40Al matrix, while the Mo-based fibers reacted moderately and the B and SiC fibers reacted severely. Experimental results are compared to theoretical thermodynamic predictions.

Draper, S. L.↗

NASA NTRS1990

Influence of testing environment on the room temperature ductility of FeAl alloys

The effects of testing atmospheres (air, O2, N2, and vacuum) on the room-temperature ductility of Fe-40Al, Fe-40Al-0.5B, and Fe-50Al alloys were investigated. The results confirmed the decrease in room-temperature ductility of Fe-rich FeAl alloys by the interaction of the aluminide with water vapor, reported previously by Liu et al. (1989). The highest ductilities were measured in the atmosphere with the lowest moisture levels, i.e., in vacuum. It was found that significant ductility is still restricted to Fe-rich alloys (Fe-40Al), as the Fe-50Al alloy remained brittle under all testing conditions. It was also found that slow cooling after annealing was beneficial, and the effect was additive to the environmental effect. The highest ductility measurements in this study were 9 percent elongation in furnace-cooled Fe-40Al and in Fe-40Al-0.5B, when tested in vacuum.

Gaydosh, D. J.↗