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Explore NASA and DOE materials research. Search alloys, composites and material properties, then open the original technical report for test conditions and results.

At least 1,747 records · Page 97

Mechanical Alloying for Making Thermoelectric Compounds

An economical room-temperature mechanical alloying process has been shown to be an effective means of making a homogeneous powder that can be hot-pressed to synthesize a thermoelectric material having reproducible chemical composition. The synthesis of a given material consists of the room temperature thermomechanical-alloying process followed b y a hot-pressing process. Relative to synthesis of nominally the same material by a traditional process that includes hot melting, this s ynthesis is simpler and yields a material having superior thermoelect ric properties.

Huang, Chen-Kuo↗

Digital Alloy Absorber for Photodetectors

In order to increase the spectral response range and improve the mobility of the photo-generated carriers (e.g. in an nBn photodetector), a digital alloy absorber may be employed by embedding one (or fraction thereof) to several monolayers of a semiconductor material (insert layers) periodically into a different host semiconductor material of the absorber layer. The semiconductor material of the insert layer and the host semiconductor materials may have lattice constants that are substantially mismatched. For example, this may performed by periodically embedding monolayers of InSb into an InAsSb host as the absorption region to extend the cutoff wavelength of InAsSb photodetectors, such as InAsSb based nBn devices. The described technique allows for simultaneous control of alloy composition and net strain, which are both key parameters for the photodetector operation.

Hill, Cory J.↗

Conductivity of a Copper-Carbon Covetic Composite

NASA is currently engaged in the development of highly electrically conductive wire for space and aviation power and propulsion applications. Higher levels of electrical conductivity and lower densities compared to copper and aluminum are needed to improve the efficiency of commercial aviation and space flight. Carbon, in various forms, is being considered as a component in composites to increase conductivity and decrease density in Cu and Al. One form of carbon that is currently receiving much interest is known as covectic. The technology currently known as covetics was first introduced by Shugart and Scherer whose patents claimed "Carbon can be incorporated into any of these metals by melting the metal, mixing the carbon into the molten metal and, while mixing, applying a current of sufficient amperage to the molten mixture such that the carbon becomes incorporated into the metal, thereby forming a single phase metal-carbon material." It is reported that in this process a conversion reaction occurs with the carbon forming covalent bonds with the host metal, and that covetic processing enables higher carbon solubility and improvements in properties. Although there is a growing body of work supporting covetic materials, it is still a very new and somewhat controversial field. Composition, density, and electrical conductivity measurements of a covetically processed alloy ingot of Cu and C, with a nominal composition of Cu-0.4wt.% C, were made. A pure Cu ingot was similarly processed for comparison. Sections of these ingots were worked into wire and tested. Only small amounts of C could be detected in the Cu-0.4wt.% C ingot, and trace amounts (0.006 wt.%) in the wire. All wires had densities very close to the full density of pure Cu, indicating a high level of Cu purity and low void fraction. Finally, the electrical conductivity of the Cu-0.4wt.% C wires were 9% lower than the samples similarly processed but without C additions. The wires made without C additions had conductivities approximately equal to pure Cu. The low conductivity of the Cu-0.4wt.% C material is believed to be due to: (1) a structure of interfaces in the wire created by collapsed voids lined with elemental C, (2) impurities, such as Fe in the Cu, which came from the added C, and (3) a small volume fraction of voids.

Degroh, Henry C.↗

The effect of 10 at.% Al addition on the hydrogen storage properties of the Ti 0.33 V 0.33 Nb 0.33 multi-principal element alloy

We report here a thorough study on the effect of 10 at.% Al addition into the ternary equimolar Ti 0.33 V 0.33 Nb 0.33 alloy on the hydrogen storage properties. Despite a decrease of the storage capacity by 20%, several other properties are enhanced by the presence of Al. The hydride formation is destabilized in the quaternary alloy as compared to the pristine ternary composition, as also confirmed by machine learning approach. The hydrogen desorption occurs at lower temperature in the Al-containing alloy relative to the initial material. Moreover, the Al presence improves the stability during hydrogen absorption/desorption cycling without significant loss of the capacity and phase segregation. Finally, this study proves that Al addition into multi-principal element alloys is a promising strategy for the design of novel materials for hydrogen storage.

36 MATERIALS SCIENCE↗

Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Over the last several decades, additive manufacturing (AM) has been primarily used for rapid prototyping or to create novel geometries that would be difficult or impossible to create by normal manufacturing methods. More recently, research has been focused on expanding the list of materials that can be made through additive manufacturing, opening a greater range of material properties for this manufacturing method. Due to the unusual conditions during AM, including the high cooling rates and voxel by voxel method of production, AM parts often have anisotropic material microstructures and properties. In this investigation, the laser power, composition, and nozzle head speed during direct metal deposition of copper-iron alloys was varied to understand how the grain structure within the printed parts could be changed and controlled. The resulting dendrite spacing was measured and compared to calculated cooling rates from Gaussian beams on flat plates under similar material and laser properties, which resulted in a cooling rate to dendrite spacing relationship following an inverse square root, as is found in other dendritic systems [Young and Kerkwood, Metall. Trans. A 6, 197–205 (1975)]. Thus, it is demonstrated that in the Cu-Fe system, dendrite spacing can be controlled through manipulation of printing parameters.

36 MATERIALS SCIENCE↗

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, J. R.↗

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, Joseph R.↗

NASA-UVA light aerospace alloy and structures technology program

The report on progress achieved in accomplishing of the NASA-UVA Light Aerospace Alloy and Structures Technology Program is presented. The objective is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys and associated thermal gradient structures in close collaboration with researchers. The efforts will produce basic understanding of material behavior, new monolithic and composite alloys, processing methods, solid and fluid mechanics analyses, measurement advances, and a pool of educated graduate students. The presented accomplishments include: research on corrosion fatigue of Al-Li-Cu alloy 2090; research on the strengthening effect of small In additions to Al-Li-Cu alloys; research on localized corrosion of Al-Li alloys; research on stress corrosion cracking of Al-Li-Cu alloys; research on fiber-matrix reaction studies (Ti-1100 and Ti-15-3 matrices containing SCS-6, SCS-9, and SCS-10 fibers); and research on methods for quantifying non-random particle distribution in materials that has led to generation of a set of computer programs that can detect and characterize clusters in particles.

Gangloff, Richard P.↗

Thermal Exposure Effects on Properties of Al-Li Alloy Plate Products

Aluminum-Lithium (AL-Li) alloys offer significant performance benefits for aerospace structural applications due to their higher specific properties compared with conventional aluminum alloys. For example, the application of an Al-Li alloy to the space shuttle external cryogenic fuel tank contributed to the weight savings that enabled successful deployment of International Space Station components. The composition and heat treatment of this alloy were optimized specifically for strength-toughness considerations for an expendable cryogenic tank. Time dependent properties related to reliability, such as thermal stability, fatigue, and corrosion, will be of significant interest when materials are evaluated for a reusable cryotank structure. As most aerospace structural hardware is weight sensitive, a reusable cryotank will be designed to the limits of the materials mechanical properties. Therefore, this effort was designed to establish the effects of thermal exposure on the mechanical properties and microstructure of one relatively production mature alloy and two developmental alloys C458 and L277. Tensile and fracture toughness behavior was evaluated after exposure to temperatures as high as 3oooF for up to IO00 hrs. Microstructural changes were also evaluated to correlate with the observed data trends. The ambient temperature parent metal data showed an increase in strength and reduction in elongation after exposure at lower temperatures. Strength reached a peak with intermediate temperature exposure followed by a decrease at highest exposure temperature. Characterizing the effect of thermal exposure on the properties of Al-Li alloys is important to defining a service limiting temperature, exposure time, and end-of-life properties.

Shah, Sandeep↗

Advanced Ceramic Matrix Composites with Multifunctional and Hybrid Structures

Ceramic matrix composites are leading candidate materials for a number of applications in aeronautics, space, energy, and nuclear industries. Potential composite applications differ in their requirements for thickness. For example, many space applications such as "nozzle ramps" or "heat exchangers" require very thin (< 1 mm) structures whereas turbine blades would require very thick parts (> or = 1 cm). Little is known about the effect of thickness on stress-strain behavior or the elevated temperature tensile properties controlled by oxidation diffusion. In this study, composites consisting of woven Hi-Nicalon (trademark) fibers a carbon interphase and CVI SiC matrix were fabricated with different numbers of plies and thicknesses. The effect of thickness on matrix crack formation, matrix crack growth and diffusion kinetics will be discussed. In another approach, hybrid fiber-lay up concepts have been utilized to "alloy" desirable properties of different fiber types for mechanical properties, thermal stress management, and oxidation resistance. Such an approach has potential for the C(sub I)-SiC and SiC(sub f)-SiC composite systems. CVI SiC matrix composites with different stacking sequences of woven C fiber (T300) layers and woven SiC fiber (Hi-Nicalon (trademark)) layers were fabricated. The results will be compared to standard C fiber reinforced CVI SiC matrix and Hi-Nicalon reinforced CVI SiC matrix composites. In addition, shear properties of these composites at different temperatures will also be presented. Other design and implementation issues will be discussed along with advantages and benefits of using these materials for various components in high temperature applications.

Singh, Mrityunjay↗

Material Characterization Report of EBR II Mark IV Fuel Element

The focus of this report is the characterization of an unirradiated as-built fuel element from the Experimental Breeder Reactor II (EBR-II) Mark IV driver fuel design. The fuel in this element is a metallic uranium-zirconium alloy, and the cladding material is HT9 stainless steel. Both the metallic fuel and cladding materials are characterized, including chemical composition, grain size, morphology, phase composition, precipitate composition, crystallography, density, and hardness.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Machine-learning and first-principles investigation of lightweight medium-entropy alloys for hydrogen-storage applications

The transition to a low-carbon economy demands efficient and sustainable energy-storage solutions, with hydrogen emerging as a promising clean-energy carrier and with metal hydrides recognized for their hydrogen-storage capacity. Here, we leverage machine learning (ML) to predict hydrogen-to-metal (H/M) ratios and solution energy by incorporating thermodynamic parameters and local lattice distortion (LLD) as key features. Our best-performing ML model provides improvements to H/M ratios and solution energies over a broad class of medium-entripy alloys (easily extendable to multi-principal-element alloys), such as Ti–Nb-X (X = Mo, Cr, Hf, Ta, V, Zr) and Co–Ni-X (X = Al, Mg, V). Ti–Nb–Mo alloys reveal compositional effects in H-storage behavior, in particular Ti, Nb, and V enhance H-storage capacity, while Mo reduces H/M and hydrogen weight percent by 40–50 %. We attributed results in molybdenum-rich alloys to slow hydrogen kinetics, as validated by our pressure-composition-temperature (PCT) isotherm experiments on pure Ti and Ti 5 Mo 95 alloys. Density functional theory (DFT) and molecular dynamics (MD) simulations also confirm that Ti and Nb promote H diffusion, whereas Mo hinders it, highlighting the interplay between electronic structure, lattice distortions, and hydrogen uptake. Notably, our Gradient Boosting Regression model identifies LLD as a critical factor in H/M predictions. Here, to aid material selection, we present two periodic tables illustrating elemental effects on (a) H 2 wt% and (b) solution energy, derived from ML, and provide a reference for identifying alloying elements that enhance hydrogen solubility and storage.

08 HYDROGEN↗

Magnesium Alloys for Space Hardware Design

There have been advances in magnesium alloy development that NASA has not taken into consideration for space hardware because of a lack of test data. Magnesium alloys offer excellent weight reduction, specific strength, and deep space radiation mitigation. Traditionally, magnesium has been perceived as having too poor of a flammability resistance and corrosion resistance to be used for flight. Recent developments in magnesium alloying has led to the formation of two alloys, WE43 and Elektron 21, which are self-extinguishing and significantly less flammable because of their composition. Likewise, an anodizing process called Tagnite was formulated to deter any concern with galvanic and saltwater corrosion. The Materials Science Branch at Kennedy Space Center is currently researching these new alloys and treatments to better understand how they behave in the harsh environment of space. Successful completion of the proposed testing should result in a more thorough understanding of modern aerospace materials and processes, and possibly the permission to use magnesium alloys in future NASA designs.

microstructure↗

Highly Thermally Conductive Hybrid Carbon Fiber Polymer Composite for Radiator Application

Carbon fiber (CF) reinforced polymer composites have been used for aerospace structures because they have low mass, high specific strength, high specific stiffness, and low life-cycle maintenance compared to aluminum alloys. However, due to their relatively low thermal conductivity, pristine CF polymer composites fail to provide effective heat flow for certain applications such as heat exchange systems and radiators. The technology described in this paper provides novel CF polymer composites that possess high thermal conductivity by incorporating pyrolytic graphite sheets (PGS). The thermal conductivities of novel hybrid PGS/CF polymer composites were measured to be about 10 to 30 times higher than that of pristine CF polymer composite, and about two times higher than that of aluminum alloy 6061. This new material with sufficient thermal conductivity is applicable to composite radiators of heat exchange systems.

Thermal Conductivity↗

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗

Progress and Challenges in Self-Healing Cementitious Materials

Concrete is the most used man-made material today consisting of a mixture of aggregates (sand, gravel, crashed rock) and paste. The paste component, made up of cement and water, cracks with time. Despite this shortcoming, research towards next-generation cement and concrete has only taken a boost in the past 10-15 years. In particular, self-healing cementitious materials is a research area that has attracted a great deal of attention. A number of reported novel formulations have demonstrated an increase in mechanical and chemical stability with respect to conventional Portland cement, through the addition of inorganic, organic, and even biological additives. This review reports on the latest advances in cement research related to the synthesis of self-healing cements applied in concrete structures. These include geopolymers, engineered cementitious materials (ECC), bacterial cement composites, microencapsulated self-healing materials, shape memory alloys (SMA), and polymer-cement composites. This work describes the performance of each cementitious material and the mechanism responsible for self-healing, including a section on the latest computational modeling studies towards this end. A detailed understanding of these various self-healing cement technologies, including their strengths and weaknesses, is critical at the time of determining the type of structures that these materials could be used for.

Fernandez, Carlos A.↗

Structure and tunable temperature coefficient of magnetization of Mn 4-x Ga x C alloys prepared by induction melting method

The magnetization of most magnetic materials decreases monotonically with increasing temperature. In this work, we found that the temperature coefficient of magnetization of Mn 4-x Ga x C alloys can be tuned from negative values to positive values by controlling the composition x. The antiperovskite type Mn 4-x Ga x C (0.05 ≤ x ≤ 0.75) alloys were prepared by using induction melting method, which is more efficient in large-scale production and obtaining full-density alloys in comparison with the traditional solid-state-reaction method. The values of the temperature coefficient of magnetization of Mn 4-x Ga x C change continuously from negative to positive with decreasing x. The Mn 4-x Ga x C alloys with highly thermal-stable magnetization is expected to present in the composition range of 0.15 < x < 0.25. The saturation magnetization of Mn 4-x Ga x C increases with increasing x, owing to the reduced number of antiferromagnetically coupled Mn atoms at the cubic corner with the face centered Mn atoms. Most Mn 4-x Ga x C alloys with varying x display near-zero remanent magnetization and coercivity at room temperature. The Currie temperature of Mn 4-x Ga x C decreases with increasing x. The x-ray photoelectron spectra of Mn 2p, Ga 2p, and C 1 s reveal distinct splitting due to the diverse chemical states of these atoms at different lattice positions and/or phases. Our work has developed a class of alloys capable of offering a desired temperature coefficient of magnetization across a broad temperature range, thereby offering a method to manipulate the thermodynamics of magnetization.

Magnetic properties↗

Directionally solidified composite systems under evaluation

The directionally solidified eutectic in-situ composites being evaluated for use as turbine materials range from ductile-ductile systems, where both matrix and reinforcement are ductile, to brittle-brittle systems, where both phases are brittle. The alloys most likely to be used in gas turbine engines in the near term are the lamellar ductile-semiductile alloys gamma prime-delta, Ni3Al-Ni3Nb and gamma/gamma prime-delta Ni,Cr,Cb,Al/Ni3Al-Ni3Nb and the fibrous ductile-brittle alloys M-MC CoTaC or NiTaC and M-M7C3(Co,Cr,Al)-(Cr,Co)7C3. Gamma-prime strengthened NiTaC alloys and a (Co,Cr,Al)-(Co,Cr)7C3 have greater tensile strength than the strongest superalloys at temperatures up to about 600 C. The gamma prime-delta and gamma/gamma prime-delta alloys in the Ni,Al,Nb(Cr) systems have greater tensile strength than the superalloys at temperatures greater than 800 C. At low stresses fibrous carbide reinforced eutectic alloys have longer lives at high temperatures than the strongest superalloys. Lamellar delta, Ni3Nb reinforced eutectic alloys have longer lives at high temperatures than the strongest superalloys at all stresses.

Ashbrook, R. L.↗