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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Completion of evaluation of manufacturing processes for B/Al composites containing 0.2mm diameter boron fibers

Four fabricators produced a total of 54 B/1100 Al, B/6061 Al, and B/2024 Al panels for evaluation. The 8 ply unidirectional, 45 to 50 volume percent, panels were made using 0.20 mm diameter boron fibers which were obtained from a single supplier. Hot press consolidation was carried out in vacuum except for one set of dry woven tape panels which were hot pressed in air. A single testing contractor conducted nondestructive inspection, metallography, fractography and mechanical property tests. The mechanical property tests included 21 and 260 C tensile tests and 21 C shear tests. Panel quality, as measured by nondestructive evaluation, was generally good as were the 21 C tensile properties. The panels hot pressed in air delaminated in the shear tests. Shear strength values were lower in these panels. But tensile strengths were not affected by the delaminations because of the relation between the tensile loading direction and the delaminations. Composite tensile strength was found to be proportional to the volume percent boron and the aluminum matrix rather than to the tape used or fabrication technique. Suitability of these composites for 260 C service was confirmed by tensile tests.

Moore, T. J.↗
DOE OSTI2025

Mechanical properties and strain localization of WA-DED printed P91 steel

This paper discusses a P91 steel block that was additively manufactured by wire arc direct energy deposition (WA-DED) followed by two types of post-process heat treatment (PPHT). Vickers microhardness and digital image correlation tensile tests were performed along the building direction. The global mechanical properties (i.e., microhardness and tensile properties) and the local mechanical responses (i.e., hardness fluctuation and strain localization) were systematically investigated. Results showed that (1) all P91 specimens showed higher strengths than American Society of Mechanical Engineers standard requirements for wrought P91 steel, (2) the as-printed P91 exhibited much higher average hardness and fluctuations than that after PPHT, (3) PPHT reduced P91 strengths but improved the ductility significantly, and (4) strain localization presented in the as-printed specimen during uniform deformation in tensile tests. The hardness fluctuation and strain localization along the building direction of the AP P91 were caused by different thermal histories received during WA-DED. The study indicated that PPHT, ideally tempering-only heat treatment, is necessary for the WA-DED printed P91 steel.

Mechanical properties↗
NASA NTRS1976

Influence of gaseous hydrogen on the mechanical properties of high temperature alloys

Tensile tests of six nickel-base and one cobalt-base alloy were conducted in 34.5 MN/sq m helium and hydrogen environments at temperatures from 297 K to 1,088 K. Mechanical properties tests of the nickel-base alloy MAR M-246 (Hf modified), in two cast conditions, were conducted in gaseous environments at temperatures from 297 K to 1,144 K and pressures from one atmosphere to 34.5 MN/sq m. The objective of this program was to obtain the mechanical properties of the various alloys proposed for use in space propulsion systems in a pure hydrogen environment at different temperatures and to compare with the mechanical properties in helium at the same conditions. All testing was conducted on solid specimens exposed to external gaseous pressure. Smooth and notched tensile properties were determined using ASTM tensile testing techniques, and creep-rupture life was determined using ASTM creep-rupture techniques. Low-cycle fatigue life was established by constant total strain and constant stress testing using smooth specimens and a closed-loop test machine.

Source record↗
NASA NTRSDate not supplied

Advances in Integrally Formed Metallic Structures

NASA Langley Research Center (LaRC) is applying flow forming technology to aerospace aluminum alloys for the manufacture of integrally stiffened cylinders that meet aircraft fuselage or launch vehicle specifications. High-strength 2xxx series alloys, in various temper/product form conditions, are being compared with medium-strength, very formable AA 6061 as the benchmark. Screening of candidate materials traditionally relies on empirical forming trials, but more recently on metrics derived from constant nominal strain rate tensile testing. In this work, the established hierarchy of formability metrics is adopted as the baseline; tensile area reduction, work hardening exponent, and modulus of resilience. The suite of metrics can be expanded based on phenomenological and mechanistic considerations of plastic flow instabilities to incorporate anisotropy ratio, rate of work hardening, and dynamic strain aging effects. Separate research thrusts at LaRC are aimed at formulating a protocol for scalable production of fully formed, defect-free components: 1) quantifying the extended set of formability metrics from constant and jump strain rate tensile tests with digital image correlation (DIC); 2) using statistically designed experiments on a vertical spin/flow forming facility (WF VUD-600®) to isolate the effect of convenient process variables, such as axial feed rate and thickness reduction; and 3) predicting the effect of feed ratio (roller translation relative to mandrel rotation speeds) on material response via process modeling using the DEFORM® simulation software. Current results will be discussed in terms of correlating intrinsic material properties with the bulk workability characteristics to successfully fabricate cylinders with complex cross-sections.

Aluminum↗
NASA NTRSDate not supplied

Effect of Heat Treatments on the Tensile Properties of Additively Manufactured 15-5 Ph Stainless Steel

This study investigated the effect of post-manufacture heat treatments on the microstructure and mechanical properties of 15-5 PH stainless steel (SS) fabricated by laser powder-directed energy deposition (LP-DED). Various heat treatment procedures (CA-H900 and CA-H1150) were conducted to evaluate their effects on the tensile behavior of LP-DED 15-5 PH SS. Scanning electron microscopy was used to characterize the microstructural features and the fracture surfaces. Tensile tests were performed to evaluate the mechanical properties at cryogenic and room temperatures. Reduction in area of CA-H1150 treated specimens after tensile tests was significantly higher than CA-H900 ones, while the ultimate tensile and yield strengths of CA-H900 specimens were higher compared to the CA-H1150 ones. The mechanical behavior of the LP-DED 15-5 PH SS in various heat treatment conditions is discussed based on their microstructures and fracture surfaces.

Laser powder directed energy deposition (LP-DED)↗
DOE OSTI2023

Strength distributions of laminated FeNi-based metal amorphous nanocomposite ribbons

Metal Amorphous Nanocomposite (MANC) materials offer low losses at high magnetic switching frequency, enabling high power density motors with increased rotational speed. While MANCs have high strength, they are brittle. The use of motor components such as a rotor consisting of brittle material presents a reliability concern. Here, a promising MANC alloy is subjected to tensile tests and failure is observed with high-speed photography. A method is developed to prepare tensile specimens of laminated MANC and epoxy layers, simulating the stacking of an epoxy-impregnated tape-wound core. Tensile tests are conducted for single layer ribbon and for five- and ten-layer stacks of laminated material with thin layers of thermosetting epoxy. Failure distributions are shown to have increasing Weibull modulus with increasing layer count. The composite MANC material system is modeled using chain-of-bundles models. Using a k-failure model, we show that single ribbon strength distribution data can be used to predict well the failure distribution of laminated stacks. The agreement occurs when the assumed ineffective length, over which load is recovered in a failed layer, is comparable to the observed interlaminar separation length.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Tensile behavior of dual-phase titanium alloys under high-intensity proton beam exposure: radiation-induced omega phase transformation in Ti-6Al-4V

A high-intensity proton beam exposure with 181 MeV energy has been conducted at Brookhaven Linac Isotope Producer facility on various material specimens for accelerator targetry applications, including titanium alloys as a beam window material. The radiation damage level of the analyzed capsule was 0.25 dpa at the beam center region with an irradiation temperature around 120 oC. Tensile tests showed increased hardness and a large decrease in ductility for the dual a+ß-phase Ti-6Al-4V Grade-5 and Grade-23 extra low interstitial alloys, with the near a-phase Ti-3Al-2.5V Grade-9 alloy still exhibiting uniform elongation of a few % after irradiation. Transmission Electron Microscope analyses on Ti-6Al-4V indicated clear evidence of a high-density of defect clusters with size less than 2 nm in each a-phase grain. The ß-phase grains did not contain any visible defects such as loops or black dots, while the diffraction patterns clearly indicated ?-phase precipitation in an advanced formation stage. The radiation-induced ?-phase transformation in the ß-phase could lead to greater loss of ductility in Ti-6Al-4V alloys in comparison with Ti-3Al-2.5V alloy with less ß-phase.google scho

Tensile Test, titanium, acclerator, proton beam↗
NASA NTRS1994

Gripping System For Mechanical Testing Of Composites

Specimens held without slippage, even at high temperatures. Improved gripping system designed to securely hold ends of specimen of composite material during creep or tensile test. Each grip includes pair of wedges having sharply corrugated gripping surfaces. Wedges held between two plates containing cavities sloped to accommodate wedges. Two such grips (one for each end) holds specimen in furnace connected to tensile test machine for creep measurements.

Mackay, Rebecca A.↗
NASA NTRS1974

High-temperature, low-cycle fatigue of advanced copper-base alloys for rocket nozzles. Part 1: Narloy Z

Short-term tensile and low-cycle fatigue data are reported for Narloy Z, a centrifugally cast, copper-base alloy. Tensile tests were performed at room temperature in air and in argon at 482, 538 and 593 C using an axial strain rate of .002/sec to the -1 power. In addition tensile tests were performed at 538 C in an evaluation of tensile properties at strain rates of .004 and .01/sec to the -1 power. Ultimate and yield strength values of about 315 and 200 MN/sq m respectively were recorded at room temperature and these decreased to about 120 and 105 respectively as the temperature was increased to 593 C. Reduction in area values were recorded in the range from 40 to 50% with some indication of a minimum ductility point at 538 C.

Conway, J. B.↗
NASA NTRS1977

Ten Deg Off-Axis Test for Shear Properties in Fiber Composites

A combined theoretical and experimental investigation was conducted to assess the suitability of the 10 deg off-axis tensile test specimen for the intralaminar shear characterization of unidirectional composites. Composite mechanics, a combined-stress failure criterion, and a finite variation across the specimen width and the relative stress and strain magnitudes at the 10 deg plane. Strain gages were used to measure the strain variation across the specimen width at specimen midlength and near the end tabs. Specimens from Mod-I/epoxy, T-300/epoxy, and S-glass/epoxy were used in the experimental program. It was found that the 10 deg off-axis tensile test specimen is suitable for intralaminar shear characterization, and it is recommended that it should be considered as a possible standard test specimen for such a characterization.

Chamis, C. C.↗
DOE OSTI2022

Using post-processing heat treatments to elucidate precipitate strengthening of additively manufactured superalloy 718

The poor machinability and extensive work hardening of Ni-based superalloys makes additive manufacturing an attractive option for producing geometrically complex components with distinct microstructures. Although previous studies show recovery of high strength at room temperature, very few studies demonstrate successful properties at elevated temperatures required for industrial applications. Here, the objectives of this study are to present a post-build heat treatment for high strength across a wide temperature range, determine the strength contribution of nanoscale precipitating phases to the overall mechanical properties of superalloy 718, and from these, provide a comprehensive microstructure-property relationship for wrought and AM 718 to guide efforts to simulate the properties of AM components. Laser powder bed fusion–produced superalloy 718 was characterized at multiple length scales using scanning electron microscopy and transmission electron microscopy in the as-built condition and with multiple heat treatments designed to form combinations of γ', γ", and δ precipitates. Uniaxial tensile tests performed from room temperature to 600 °C on subsize specimens determined the yield strength, elastic modulus, ultimate tensile strength, fracture stress, and uniform elongation. Precipitates in this work proved to be weak barriers to dislocation motion through a dispersed barrier model, but they provided strength to the alloy through their consistent high density. The relative contribution to the yield strength from γ" remained consistent between 48% and 57% of the total strength up to 600 °C, the primary influence on the high temperature strength of superalloy 718. The strength factors for γ" and δ precipitates were found to trend inversely with tensile test temperature and may be attributable to the differences in precipitate coherency. A post-build heat treatment is recommended to maintain high strength at elevated temperatures. A quantitative microstructure-property relationship, dependent on precipitate size, density, and morphology, was derived and can estimate the yield strength across a wide temperature range applicable to the operational regimes for superalloy 718.

36 MATERIALS SCIENCE↗
NASA NTRS1977

10-deg off-axis test for shear properties in fiber composites

A combined theoretical and experimental investigation was conducted to assess the suitability of the 10-deg off-axis tensile test specimen for the intralaminar shear characterization of unidirectional composites. Composite mechanics, a combined-stress failure criterion, and a finite-element analysis were used to determine theoretically the stress-strain variation across the specimen width and the relative stress and strain magnitudes at the 10-deg plane. Strain gages were employed to measure the strain variation across the specimen width at specimen midlength and near the end tabs. Specimens from Mod-I/epoxy, T-300/epoxy, and S-glass/epoxy were used in the experimental program. It was found that the 10-deg off-axis tensile test specimen is suitable for intralaminar shear characterization, and it is recommended that it should be considered as a possible standard test specimen for such a characterization.

Chamis, C. C.↗
NASA NTRS1980

Anisotropy of nickel-base superalloy single crystals

The effects of crystal orientation on the mechanical properties of single crystals of the nickel-based superalloy Mar-M247 are investigated. Tensile tests at temperatures from 23 to 1093 C and stress rupture tests at temperatures from 760 to 1038 C were performed for 52 single crystals at various orientations. During tensile testing between 23 and 760 C, single crystals with high Schmid factors were found to be favorably oriented for slip and to exhibit lower strength and higher ductility than those with low Schmid factors. Crystals which required large rotations to become oriented for cross slip were observed to have the shortest stress rupture lives at 760 C, while those which required little or no rotation had the longest lives. In addition, stereographic triangles obtained for Mar-M247 and Mar-M200 single crystals reveal that crystals with orientations near the -111 had the highest lives, those near the 001 had high lives, and those near the 011 had low lives.

Mackay, R. A.↗
NASA NTRS1976

Observations on the relationship of structure to the mechanical properties of thin TD-NiCr sheet

A study of the relationship between structure and mechanical properties of thin TD-NiCr sheet indicated that the elevated temperature tensile, stress-rupture, and creep strength properties are dependent on grain aspect ratio and sheet thickness. In general, the strength properties increase with increasing grain aspect ratio and sheet thickness. Tensile testing revealed an absence of ductility at elevated temperatures (not less than 1144 K). Significant creep damage as determined by subsequent tensile testing at room temperature occurs after very small amounts (less than 0.1%) of prior creep deformation over the temperature range 1144-1477 K. A threshold stress for creep appears to exist. Creep exposure below the threshold stress at T not less than 1366 K results in almost full retention of room temperature tensile properties.

Whittenberger, J. D.↗
NASA NTRS2004

Elastomer Filled With Single-Wall Carbon Nanotubes

Experiments have shown that composites of a silicone elastomer with single-wall carbon nanotubes (SWNTs) are significantly stronger and stiffer than is the unfilled elastomer. The large strengthening and stiffening effect observed in these experiments stands in contrast to the much smaller strengthening effect observed in related prior efforts to reinforce epoxies with SWNTs and to reinforce a variety of polymers with multiple-wall carbon nanotubes (MWNTs). The relative largeness of the effect in the case of the silicone-elastomer/SWNT composites appears to be attributable to (1) a better match between the ductility of the fibers and the elasticity of the matrix and (2) the greater tensile strengths of SWNTs, relative to MWNTs. For the experiments, several composites were formulated by mixing various proportions of SWNTs and other filling materials into uncured RTV-560, which is a silicone adhesive commonly used in aerospace applications. Specimens of a standard "dog-bone" size and shape for tensile testing were made by casting the uncured elastomer/filler mixtures into molds, curing the elastomer, then pressing the specimens from a "cookie-cutter" die. The results of tensile tests of the specimens showed that small percentages of SWNT filler led to large increases in stiffness and tensile strength, and that these increases were greater than those afforded by other fillers. For example, the incorporation of SWNTs in a proportion of 1 percent increased the tensile strength by 44 percent and the modulus of elasticity (see figure) by 75 percent. However, the relative magnitudes of the increases decreased with increasing nanotube percentages because more nanotubes made the elastomer/nanotube composites more brittle. At an SWNT content of 10 percent, the tensile strength and modulus of elasticity were 125 percent and 562 percent, respectively, greater than the corresponding values for the unfilled elastomer.

Files, Bradley S.↗
DOE OSTI2020

Mechanical Properties and Deformation Behavior of Additively Manufactured 316L Stainless Steel (FY2020)

The Transformational Challenge Reactor (TCR) program plans to build most of the TCR core components through additive manufacturing (AM) processes. These processes include laser powder bed fusion (LPBF) for the metallic (316L) components and the newly developed combined process of binderjet printing and chemical vapor infiltration (CVI) for the SiC fuel matrix. Mechanical testing and characterization tasks have been carried out since the beginning of the TCR program to (1) build a property database for the AM materials that will be used in TCR core and (2) to assess the materials’ performance in TCR-relevant conditions. This document reports the outcome of the testing and characterization efforts for the fiscal year with a focus on the mechanical performance data of AM 316L stainless steel (SS). Baseline tensile testing over a wide temperature range of room temperature–600 °C was completed for the AM 316L alloy in as-built, stress-relieved, and solution-annealed conditions. The as-built 316L showed the highest strength, and the alloy after the post-build treatments showed reduced strengths in the low-strain range. However, the strength differences among the AM materials became insignificant in the later part of deformation. Furthermore, regardless of post-build processing, the AM 316L SS showed higher strength and comparable ductility when compared with wrought 316L SS. Thermal creep testing and microstructural evolution during creep deformation were also performed under selected conditions. It was found that the AM 316L steel showed the best creep resistance in the stress-relieved condition. In-situ tensile tests were performed using scanning electron microscopy and 1-ID beamline at the Advanced Photon Source to elucidate the deformation and fracture behavior of AM 316L and the evolution of crystalline stress, dislocations, and pore distribution. Using these in-situ testing data, an in-depth analysis of the roles of microstructural features in deformation and fracture processes is presented herein. The final section of the document introduces ongoing and future activities for materials testing and characterization, including irradiation effect studies and ball punch testing on AM 316L and AM IN718 alloys.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Wrought FeCrAl alloy (C26M) cladding behavior and burst under simulated loss-of-coolant accident conditions

Cladding burst experiments for FeCrAl cladding were performed in the Severe Accident Test Station facility at Oak Ridge National Laboratory. These experiments were simulated using the BISON fuel performance code to better understand the cladding plastic behavior and failure under simulated loss-of-coolant accident conditions. 3D cladding surface boundary conditions were generated using composite axial and azimuthal profiles from experiment thermocouple data. To improve the simulation analysis capabilities in BISON for cladding burst behavior, new thermal creep, plasticity, and failure stress models specific to C26M, a wrought FeCrAl alloy, were developed and implemented. Initial cladding burst results indicated a general underprediction in the failure temperature of the six cladding burst simulations versus the observed failure temperatures. Close investigation of the experiment timing versus the underlying tensile test data revealed that, compared with the tensile specimens, the cladding tubes did not experience the same long holding time at high temperatures. New tensile tests were performed at high temperatures using a temperature ramp similar to the simulated loss-of-coolant accident experiments. These new tensile curves showed an approximately 80% increase in the ultimate tensile strength of the C26M alloy, indicating that a holding time of 10 min at 700 °C and 800 °C allows annealing to change the material microstructure. Using the updated tensile properties, the burst temperatures and stresses from the simulations showed remarkable agreement with the experimental results. This study was then extended by varying the initial pressure to highlight the burst temperature difference between standard Zircaloy-4 and C26M cladding under equivalent conditions. The results show that C26M has a burst temperature that is approximately 70–130 K greater than that of Zircaloy-4. In conclusion, these modeling predictions can be further improved by collecting high-temperature tensile data for C26M beyond the temperature ranges used in this work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

10° off-axis testing of CFRP using DIC: A study on strength, strain and modulus

For the determination of the shear properties such as strength, strain and modulus of unidirectionally reinforced composites, nearly a dozen measurement techniques exist, several of which have found their way into standards. One non-standardized method for sheet materials is the 10° off-axis tensile test of unidirectional coupons. The current work focuses on the experimental investigation of tensile testing of CFRP-UD coupon specimens using the 10° off-axis test and DIC strain mapping to measure the full-field deformation response. A sensitivity analysis on the measured stresses, strains and moduli is performed by varying the aspect ratio of the specimens and the location of strain measurement. Test related uncertainties such as the loading angle and specimen preparation details are investigated and quantified with the help of these full-field DIC measurements.

42 ENGINEERING↗