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Hot cracking tendencies evaluation of fusion welds of Inconel 718 alloy after different heat treatments
Thermophysical properties of aluminum, beryllium, Inconel, stainless steel, and titanium alloys and primary oxides
The effect of material porosity on final part distortion and residual stresses in a selective laser sintering manufacturing simulation is presented here. A time-dependent thermo-mechanical model is used with the open-source FEA software CalculiX. Effective homogenized material properties for Inconel 625 are precomputed using NASA’s Micromechanics Analysis Code with the Generalized Method of Cells. The evolving porosity of the material is estimated with each pass of the laser beam during simulation runtime. A comparison with a homogenous model and the evolving model shows that the model with evolving porosity predicts larger distortions with greater residual stresses.
Far-field high-energy X-ray diffraction microscopy (ff-HEDM) and the crystal plasticity finite element method (CPFEM) are used to investigate the role of grain-scale (Type-II) residual stresses on the fatigue life of additively manufactured (AM) Inconel alloy 625 (IN-625). Grain-averaged orientations, centroids, and residual elastic strain tensors from ff-HEDM data are used to instantiate a crystal plasticity model to simulate the effect of residual stresses at the grain scale. Simulation results indicate that the presence of tensile residual strains increase stress localization and heterogeneity within grains, triggering an earlier onset of plasticity. A microscale fatigue indicator parameter (FIP) is computed to model the impact of these residual strains on the cycles to fatigue crack nucleation. The crack nucleation model, based on the computed FIPs, predicts a significant reduction in the number of cycles for fatigue crack nucleation for mid- and high-cycle fatigue due to the residual strain induced localization, while the residual strains have minimal impact on low-cycle fatigue life.
Design and fabrication procedures are discussed of a brazed-ribtype thrust chamber fabricated from stainless steel or inconel for a Sooo-lb thrust 20: 1 expansion-area-ratio regeneratively cooled liquidpropellant rocket engine which is designated as the JPL 6K Engine and operates at a chamber pressure of 150 psia. Hydrazine is used as the fuel and regenerative coolant and nitrogen tetroxide as the oxidizer. The nozzle-throat diameter is 5.42 in. The thrust chamber consists of a sheet-metal gas-side liner with longitudinal ribs spotwelded and brazed to the outer surface. Wire is wrapped over the ribs circumferentially, spot-welded to the ribs, and brazed. The liner, ribs, and wire form the coolant-passage walls. There are three basic advantages to this type of thrust chamber: light weight, ease of fabrication, and comparatively low cost. The total dry weight of a thrust chamber of this type and size made of 347 stainless steel is 46.2 lb, and the wet weight is 56.3 Ib. A total of 87 static engine tests were made on 19 of 23 thrust chambers fabricated by this technique. Four of the chambers tested had an expansion-area ratio of 20:1, and 15, which were shorter but had the same throat diameter, had an expansion-area ratio of 3.5:l. Accumulated test time was 1926 sec, including 558 sec regenerative cooling with hydrazine and 1368 sec cooling with water. One 20:l thrust chamber was subjected to 16 separate engine tests, with an accumulated test time of 399 sec, and was still in very good operating condition after the tests were completed. With water flowing through the coolant passages at 10 lb/sec, the measured nominal pressure drop between coolant manifolds of a 20:l thrust chamber wrapped with flat wire was 17.2 psi.
Local values of heat transfer coefficients have been measured experimentally for helium and hydrogen gas flowing through an electrically heated inconel tube. The experiment was conducted primarily to determine the effect on the heat transfer coefficient of a large density change, radially, in the heat transfer fluid. This large density change was accomplished with relatively high surface temperatures as compared to fluid bulk temperatures or more commonly referred to as high surface to fluid bulk temperature ratio. The large temperature ratio was achieved by precooling the gas with liquid nitrogen. Data were measured for local values of surface to fluid bulk temperature ratios up to 4.5, Reynolds numbers in the turbulent flow region, surface temperatures up to 2300° R, heat flux up to 1,600,000 Btu/(hr)(sq ft) and length to diameter ratio of 250. A comparison of this data with the conventional heat transfer· correlation equation (Dittus-Boelter eq.) is shown on a curve of Nusselt number divided by Prandtl number versus the Reynolds number. The gas properties were evaluated at the film temperature and the Reynolds number was modified by evaluating the velocity term at the fluid bulk temperature and the density at the film temperature.
As thrust levels increase and as rocket engines fire for longer periods of time, the difficulties encountered in the protection of critical components from the effects of excessively high temperatures greatly increase. To protect these components a series of filled elastomeric composites have been evaluated. A brief discussion is presented of the problems of hot gas recirculation, radiation, and base plane heating with particular reference to large, clustered, liquid propellant rocket engines. The effect on components is discussed and an evaluation of a series of insulators based on filled elastomeric composites is presented. The evaluations are based on specialized thermal tests which were designed to simulate as far as possible, conditions during flight. The most promising of these elastomeric composites are compared to three alternative insulative systems, a filled, castable ceramic, a metal foil-silica fiber batting, and an asbestos-inconel wire mesh composite, in terms of weight, cost, and ease of fabrication and repair.
A study has been made of a flare-cylinder configuration to investigate its feasibility as a reentry body of an intermediate range ballistic missile. Factors considered were heating, weight, stability, and impact velocity. A series of trajectories covering the possible range of weight-drag ratios were computed for simple truncated nose shapes of varying pointedness, and hence varying weight-drag ratios. Four trajectories were chosen for detailed temperature computation from among those trajectories estimated to be possible. Temperature calculations were made for both "conventional" (for example, copper, Inconel, and stainless steel) and "unconventional" (for example, beryllium and graphite) materials. Results of the computations showed that an impact Mach number of 0.5 was readily obtainable for a body constructed from conventional materials. A substantial increase in subsonic impact velocity above a Mach number of 0.5 was possible without exceeding material temperature limits. A weight saving of up to 134 pounds out of 822 was possible with unconventional materials. This saving represents 78 percent of the structural weight. Supersonic impact would require construction of the body from unconventional materials but appeared to be well within the range of attainability.
Dry blasting with glass beads through a nozzle assembly descales both the outside and inside surfaces of tubes of Inconel 718 used for the distribution of gaseous oxygen. The inside of the nozzle is coated with polyurethane and the deflector with a commercially available liquid urethane rubber.
The Saturn S-II stage and the Apollo spacecraft will include in their design and construction various pressurized tubing systems that will encounter service temperatures of 280° F to -423° F. Design engineering and reliability requirements and weight restrict ions have dictated new concepts to assure leak-tight joints for rocket engine fuel lines, pressurization systems, utility systems, and hydraulic systems. An investigation was initiated at North American Aviation, Inc., Space and Information Systems Division, utilizing the in-place automatically controlled miniaturized fusion-welding equipment originally developed by the Los Angeles Division of NAA and modified to meet the needs of Apollo and Saturn welded tubular systems. The objective was to make circumferential flanged weld joints in any position in 304L stainless for Saturn S-II and sleeve-type joints in 304L for Apollo. Inconel X, commercially pure titanium, 5052-0 aluminum, and 6061 T6 aluminum were also tested experimentally. Extensive environmental, static, and dynamic testing programs were conducted to determine the as-welded mechanical properties, design allowables, and reliability for the tube joints. This paper discusses both the experimental and production phases. Subsequently, the new tube welding process was approved and incorporated into manufacturing fabrication methods for tube joining.
The behavior of compression springs is affected by increased temperatures. The most significant factors affecting springs are a loss of load and length (relaxation), and a change in the modulus of rigidity. Relaxation will reduce preset loads or change the location of supported components whereas a change in the modulus of rigidity will alter the spring rate. Both factors must be taken into account when designing compression springs. Curves and equations are presented (for music wire, 18-8 stainless steel, 17-7 PH, and Inconel-X) which can aid in the design of compression springs for use at elevated temperatures.
Heat transfer coefficients for helium and hydrogen gas flowing through electrically heated Inconel tube
Gold undercoat prevents blistering in the silver plating of Inconel 718 seals from steam at high temperatures. The undercoat is diffused into the surface of the parent metal by baking prior to silver plating.
Mn, S and rare earth additions influence on Inconel alloy weld microfissuring including material, hot ductility and tensile strength data
Arc-plasma-sprayed layered coating of graded Inconel and zirconia protects film-coolant ring below injector plate of rocket engine combustion chamber. Interfacial temperature is designed for minimum buildup of stress and to avoid melting of the metal phase in the graded layers.
Inconel compression springs for long term space power system operation in high temperature vacuum
Thermal conductivity, electrical resistivity, Lorentz ratio and thermopower of aerospace alloys at cryogenic temperatures, considering Inconel, Hastelloy, Ti and Al alloys
Inconel-steel, puddle-welded rotor spin and magnetic testing for use in 36,000 rpm Lundell alternator