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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development of Directed Energy Deposited NASA HR-1 to Optimize Properties for Liquid Rocket Engine Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This poster will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

NASA HR-1↗
NASA NTRS1971

Generation of long time creep data on refractory alloys at elevated temperatures

Ultrahigh vacuum creep tests were conducted on tantalum, tungsten, and molybdenum alloys to develop creep data and to evaluate the influence of liquid lithium exposure on the creep behavior of the tantalum alloy T-111. Test conditions were generally selected to provide 1% creep in 1000 to 10,000 hours, with test temperatures ranging from 1600 to 2912 F (1144 to 1873 K). Tests on T-111 specimens exposed to vacuum and to liquid lithium for various times and temperatures showed large reductions in creep strength for exposures in the 1800 to 1900 F (1255 to 1310 K) range. Tests on the ASTAR 811c showed a significant influence of grain size on the creep strength of this material, with larger grain size specimens being significantly stronger above the equicohesive temperature of 2000 F (1366 K).

Sheffler, K. D.↗
NASA NTRSDate not supplied

Development and Optimization of Additively Manufactured NASA HR-1 for Space Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This presentation will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

Additive Manufacturing↗
NASA NTRS1971

Generation of long time creep data on refractory alloys at elevated temperatures

Ultrahigh vacuum creep tests were performed on tungsten, molybdenum, and tantalum alloys to develop design creep data and to evaluate the influence of liquid lithium exposure on the creep resistance of a tantalum alloy. Test conditions were generally selected to provide 1% creep in 1000 to 10,000 hours, with the test temperatures ranging between 1600 and 2900 F (1144 K and 1866 K). One percent creep life data from a tantalum-base T-111 alloy (Ta-8%W-2%Hf) were analyzed using a station function method to provide an improved parametric representation of the T-111 data. In addition, the minimum creep rate data from an ASTAR 811C alloy (Ta-8%W-1%Re-0.7%Hf0.025%C) were analyzed to determine the stress and temperature dependence of creep rate. Results of this analysis indicated that the activation energy for creep decreased from about 150 Kcal/mole (5130 J/mole) above 2400 F (1589 K) to about 110 Kcal/mole (3760 J/mole) below 2000 F (1361 K). This temperature range corresponds to the range where the creep mechanism changes from grain boundary sliding to intragranular creep.

Sheffler, K. D.↗
NASA NTRS1980

The effect of zirconium on the isothermal oxidation of nominal Ni-14Cr-24Al alloys

The isothermal oxidation of Ni-14Cr-24Al-xZr-type alloys was performed in still air at 1100, 1150, and 1200 C for times up to 200 hr. The zirconium content of the alloys varied from 0-0.63 atom percent (a/o). The oxidized surfaces were studied by optical microscopy, X-ray diffraction, and scanning electron microscopy. The base alloy was an alumina former with the zirconium-containing alloys also developing some ZrO2. The addition of zirconium above 0.066 a/o increased the rate of weight gain relative to the base alloy. Due to oxide penetratio, the weight gain increased with Zr content; however, the scale thickness did not increase. The Zr did increase the adherence of the oxide, particularly at 1200 C. The delta W/A vs. time data fit the parabolic model of oxidation. The specific diffusion mechanism operative could not be identified by analysis of the calculated activation energies. Measurements of the Al2O3 scale lattice constants yielded the same values for all alloys.

Kahn, A. S.↗
NASA NTRS1980

Fatigue properties of MA 6000E, a gamma-prime strengthened ODS alloy

MA 6000E is a corrosion resistant, gamma-prime strengthened ODS alloy under development for advanced turbine blade applications. The high temperature, 1093 C, rupture strength is superior to conventional nickel-base alloys. This paper addresses the fatigue behavior of the alloy. Excellent properties are exhibited in low and high cycle fatigue and also thermal fatigue. This is attributed to a unique combination of microstructural features, i.e., a fine distribution of dispersed oxides and other nonmetallics, and the highly elongated grain structure which advantageously modify the deformation characteristics and crack initiation and propagation modes from that characteristic of conventional gamma-prime hardened superalloys.

Kim, Y. G.↗
NASA NTRS1989

Macrosegregation and nucleation in undercooled Pb-Sn alloys

A technique resulting in large undercoolings in bulk samples (23g) of lead-tin alloys was developed. Samples of Pb-12.5 wt percent Sn, Pb-61 wt percent Sn, and Pb-77 wt percent Sn were processed with undercoolings ranging from 4 to 34 K and with cooling rates varying between 0.04 and 4 K/sec. The nucleation behavior of the Pb-Sn system was found to be nonreciprocal. The solid Sn phase effectively nucleated the Pb phase of the eutectic; however, large undercoolings developed in Sn-rich eutectic liquid in the presence of the solid Pb phase. This phenomenon is believed to be mainly the result of differences in interfacial energies between solid Sn-eutectic liquid, and solid Pb-eutectic liquid rather than lattice misfit between Pb and Sn. Large amounts of segregation developed in the highly undercooled eutectic ingots. This macrosegregation was found to increase as undercooling increases. Macrosegregation in these undercooled eutectic alloys was found to be primarily due to a sink/float mechanism and the nucleation behavior of the alloy. Lead-rich dendrites are the primary phase in the undercooled eutectic system. These dendrites grow rapidly into the undercooled bath and soon break apart due to recalescence and Sn enrichment of the liquid. These fragmented Pb dendrites are then free to settle to the bottom portion of the ingot causing the macrosegregation observed in this study. A eutectic Pb-Sn alloy undercooled 20 K and cooled at 4 K/sec had a composition of about Pb-72 wt percent Sn at the top and 55 percent Sn at the bottom.

Degroh, Henry C., III↗
NASA NTRS1989

Macrosegregation and nucleation in undercooled Pb-Sn alloys

A novel technique resulting in large undercoolings in bulk samples (23 g) of lead-tin alloys was developed. Samples of Pb-12.5 wt percent Sn, Pb-61.9 wt.% Sn, and Pb-77 wt.% Sn were processed with undercoolings ranging from 4 to 34 K and with cooling rates varying between 0.04 and 4 K/s. The nucleation behavior of the Pb-Sn system was found to be nonreciprocal. The solid Sn phase effectively nucleated the Pb phase of the eutectic; however, large undercoolings developed in Sn-rich eutectic liquid in the presence of the solid Pb phase. This phenomenon is believed to be mainly the result of differences in interfacial energies between solid Sn-eutectic liquid, and solid Pb-eutectic liquid rather than lattice misfit between Pb and Sn. Large amounts of segregation developed in the highly undercooled eutectic ingots. This macrosegregation was found to increase as undercooling increases. Macrosegregation in these undercooled eutectic alloys was found to be primarily due to a sink/float mechanism and the nucleation behavior of the alloy. Lead-rich dendrites are the primary phase in the undercooled eutectic system. These dendrites grow rapidly into the undercooled bath and soon break apart due to recalescence and Sn enrichment of the liquid. These fragmented Pb dendrites are then free to settle to the bottom portion of the ingot causing the macrosegregation observed in this study. A eutectic Pb-Sn alloy undercooled 20 K and cooled at 4 K/s had a composition of about Pb-72 wt.% Sn at the top and 55% Sn at the bottom.

Degroh, Henry C., III↗
NASA NTRS1970

Molding procedure for casting a variety of alloys

General procedure and molding sand composition for preparing molds usable for casting variety of alloys are developed. Molds are prepared from mixture of sand, sodium silicate binder, and organic liquid ester. Castings of radiographic quality are produced from various alloys.

Fontes, M. J.↗
NASA NTRS1971

Development of oxidation resistance in thoriated nickel-chromium base alloys

A pack process was developed which permits the introduction of nearly six weight percent aluminum into solid solution in the near-surface region of TDNiCr (Ni-20Cr-2ThO2. At this aluminum concentration an adherent alumina scale is produced on the alloy surface upon exposure to an environment of 1330 n/sq m (10 torr) or 101,000 n/sq m (760 torr) air at temperatures of 1093 C (2000 F) and 1204 C (2200 F). Room temperature mechanical properties of the aluminized alloys compare favorably with those of TDNiCr as received. While diffusivities for aluminum are a factor of three higher than those for chromium in TDNiCr or Ni-20Cr, the diffusion rates are similar for either of these elements in the thoriated or unthoriated alloy for a given temperature and grain size.

Seltzer, M. S.↗
NASA NTRS1977

Phase relations in the Fe-Ni-Cr-S system and the sulfidation of an austenitic stainless steel

The stability fields of various sulfide phases that form on Fe-Cr, Fe-Ni, Ni-Cr and Fe-Cr-Ni alloys were developed as a function of temperature and the partial pressure of sulfur. The calculated stability fields in the ternary system were displayed on plots of log P sub S sub 2 versus the conjugate extensive variable which provides a better framework for following the sulfidation of Fe-Cr-Ni alloys at high temperatures. Experimental and estimated thermodynamic data were used in developing the sulfur potential diagrams. Current models and correlations were employed to estimate the unknown thermodynamic behavior of solid solutions of sulfides and to supplement the incomplete phase diagram data of geophysical literature. These constructed stability field diagrams were in excellent agreement with the sulfide phases and compositions determined during a sulfidation experiment.

Jacob, K. T.↗
NASA NTRS1989

Identification of a cast iron alloy containing nonstrategic elements

A program was performed to address the mechanical and environmental needs of Stirling engine heater head and regenerator housing components, while reducing the dependence on strategic materials. An alloy was developed which contained no strategic elemental additions per se. The base is iron with additions of manganese, molybdenum, carbon, silicon, niobium, and ferro-chromium. Such an alloy should be producible on a large scale at very low cost. The resulting alloy, designated as NASAUT 4G-Al, contained 15 Mn, 15 Cr, 2 Mo, 1.5 C, 1.0 Si, 1.0 Nb (in weight percent) with a balance of Fe. This alloy was optimized for chemistry, based upon tensile strength, creep-rupture strength, fracture behavior, and fatigue resistance up to 800 C. Alloys were also tested for environmental compatibility. The microstructure and mechanic properties (including hardness) were assessed in the as-cast condition and following several heat treatments, including one designed to simulate a required braze cycle. The alloy was fabricated and characterized in the form of both equiaxed and columnar-grained castings. The columnar grains were produced by directional solidification, and the properties were characterized in both the longitudinal and transverse orientations. The NASAUT 4G-Al alloy was found to be good in cyclic-oxidation resistance and excellent in both hydrogen and hot-corrosion resistance, especially in comparison to the baseline XF-818 alloy. The mechanical properties of yield strength, stress-rupture life, high-cycle-fatigue resistance, and low-cycle-fatigue resistance were good to excellent in comparison to the current alloy for this application, HS-31 (X-40), with precise results depending in a complex manner on grain orientation and temperature. If required, the ductility could be improved by lowering the carbon content.

Cooper, C. V.↗
NASA NTRS1982

Solidification of undercooled liquids

During rapid solidification processing (RSP) the amount of liquid undercooling is an important factor in determining microstructural development by controlling phase selection during nucleation and morphological evolution during crystal growth. While undercooling is an inherent feature of many techniques of RSP, the deepest undercoolings and most controlled studies have been possible in carefully prepared fine droplet samples. From past work and recent advances in studies of nucleation kinetics it has become clear that the initiation of crystallization during RSP is governed usually by heterogeneous sites located at surfaces. With known nucleant sites, it has been possible to identify specific pathways of metastable phase formation and microstructural development in alloys. These advances have allowed for a clearer assessment of the interplay between undercooling, cooling rate and particle size statistics in structure formation. New approaches to the examination of growth processes have been developed to follow the thermal behavior and morphology in small samples in the period of rapid crystallization and recalescence. Based upon the new experimental information from these studies, useful models can be developed for the overall solidification process to include nucleation behavior, thermodynamic constraints, thermal history, growth kinetics, solute redistribution and resulting structures. From the refinement of knowledge concerning the underlying factors that govern RSP a basis is emerging for an effective alloy design and processing strategy.

Perepezko, J. H.↗
NASA NTRS1995

NASA-UVa light aerospace alloy and structures technology program supplement: Aluminum-based materials for high speed aircraft

This report on the NASA-UVa light aerospace alloy and structure technology program supplement: Aluminum-Based Materials for High Speed Aircraft covers the period from July 1, 1992. The objective of the research is to develop aluminum alloys and aluminum matrix composites for the airframe which can efficiently perform in the HSCT environment for periods as long as 60,000 hours (certification for 120,000 hours) and, at the same time, meet the cost and weight requirements for an economically viable aircraft. Current industry baselines focus on flight at Mach 2.4. The research covers four major materials systems: (1) Ingot metallurgy 2XXX, 6XXX, and 8XXX alloys, (2) Powder metallurgy 2XXX alloys, (3) Rapidly solidified, dispersion strengthened Al-Fe-X alloys, and (4) Discontinuously reinforced metal matrix composites. There are ten major tasks in the program which also include evaluation and trade-off studies by Boeing and Douglas aircraft companies.

Starke, E. A., Jr.↗
NASA NTRS1992

Microstructural observations in rapidly-solidified and heat-treated Ni3Al-Cr alloys

The microstructural development following heat treatments of several rapidly-solidified Ni3Al-Cr and Ni3Al-Cr-B alloys is presented. Depending on composition, the as-solidified samples were either 100 percent gamma-prime phase - in the form of fine antiphase domains (APD) - or a mixture of gamma-prime (APDs) and beta phases. Upon annealing, the as-solidified microstructures transform to either APD-free gamma-prime or mixtures of gamma and gamma-prime phases. For those compositions where the quenched microstructures were 100 percent gamma-prime it was observed that APD coarsening followed conventional grain-growth kinetics, but when gamma phase precipitated on the APD boundaries the rate constant changed abruptly while the time exponent remained unaffected. It was also found that alloys containing critical amounts of chromium and boron are susceptible to precipitation of the boride Cr5B3.

Carro, G.↗
NASA NTRS2008

Thermal Expansion Studies of Selected High Temperature Thermoelectric Materials

Radioisotope thermoelectric generators (RTGs) generate electrical power by converting the heat released from the nuclear decay of radioactive isotopes (typically plutonium-238) into electricity using a thermoelectric converter. RTGs have been successfully used to power a number of space missions and have demonstrated their reliability over an extended period of time (tens of years) and are compact, rugged, radiation resistant, scalable, and produce no noise, vibration or torque during operation. System conversion efficiency for state-of-practice RTGs is about 6% and specific power less than or equal to 5.1 W/kg. Higher specific power would result in more on-board power for the same RTG mass, or less RTG mass for the same on-board power. The Jet Propulsion Laboratory has been leading, under the advanced thermoelectric converter (ATEC) project, the development of new high-temperature thermoelectric materials and components for integration into advanced, more efficient RTGs. Thermoelectric materials investigated to date include skutterudites, the Yb14MnSb11 compound, and SiGe alloys. The development of long-lived thermoelectric couples based on some of these materials has been initiated and is assisted by a thermo-mechanical stress analysis to ensure that all stresses under both fabrication and operation conditions will be within yield limits for those materials. Several physical parameters are needed as input to this analysis. Among those parameters, the coefficient of thermal expansion (CTE) is critically important. Thermal expansion coefficient measurements of several thermoelectric materials under consideration for ATEC are described in this paper. The stress response at the interfaces in material stacks subjected to changes in temperature is discussed, drawing on work from the literature and project-specific tools developed here. The degree of CTE mismatch and the associated effect on the formation of stress is highlighted.

silicon germanium↗
NASA NTRS1986

Characterizing Semiconductor Alloys for Infrared Sensors

Report presents results of continuing program aimed at characterizing mercury/cadmium/tellurium alloys and eventually developing improved methods of preparing alloys for use as infrared sensors. Work covered by report includes series of differential thermal analysis (DTA) measurements of alloy compositions with x varied from 9 to 1 in 0.1 increments.

Lehoczky, B. S. L.↗
NASA NTRS2008

Advanced Lithium-Ion Cell Development for NASA's Constellation Missions

The Energy Storage Project of NASA s Exploration Technology Development Program is developing advanced lithium-ion batteries to meet the requirements for specific Constellation missions. NASA GRC, in conjunction with JPL and JSC, is leading efforts to develop High Energy and Ultra High Energy cells for three primary Constellation customers: Altair, Extravehicular Activities (EVA), and Lunar Surface Systems. The objective of the High Energy cell development is to enable a battery system that can operationally deliver approximately 150 Wh/kg for 2000 cycles. The Ultra High Energy cell development will enable a battery system that can operationally deliver 220 Wh/kg for 200 cycles. To accomplish these goals, cathode, electrolyte, separator, and safety components are being developed for High Energy Cells. The Ultra High Energy cell development adds lithium alloy anodes to the component development portfolio to enable much higher cell-level specific energy. The Ultra High Energy cell development is targeted for the ascent stage of Altair, which is the Lunar Lander, and for power for the Portable Life support System of the EVA Lunar spacesuit. For these missions, mass is highly critical, but only a limited number of cycles are required. The High Energy cell development is primarily targeted for Mobility Systems (rovers) for Lunar Surface Systems, however, due to the high risk nature of the Ultra High Energy cell development, the High Energy cell will also serve as a backup technology for Altair and EVA. This paper will discuss mission requirements and the goals of the material, component, and cell development efforts in further detail.

Reid, Concha M.↗