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At least 253 records · Page 14

Oxidation of Copper Alloy Candidates for Rocket Engine Applications

The gateway to affordable and reliable space transportation in the near future remains long-lived rocket-based propulsion systems; and because of their high conductivities, copper alloys remain the best materials for lining rocket engines and dissipating their enormous thermal loads. However, Cu and its alloys are prone to oxidative degradation -- especially via the ratcheting phenomenon of blanching, which occurs in situations where the local ambient can oscillate between oxidation and reduction, as it does in a H2/02- fuelled rocket engine. Accordingly, resistance to blanching degradation is one of the key requirements for the next generation of reusable launch vehicle (RLV) liner materials. Candidate copper alloys have been studied with a view to comparing their oxidation behavior, and hence resistance to blanching, in ambients corresponding to conditions expected in rocket engine service. These candidate materials include GRCop-84 and GRCop-42 (Cu - Cr-8 - Nb-4 and Cu - Cr-4 - Nb-2 respectively); NARloy-Z (Cu-3%Ag-0.5%Y), and GlidCop (Cu-O.l5%Al2O3 ODS alloy); they represent different approaches to improving the mechanical properties of Cu without incurring a large drop in thermal conductivity. Pure Cu (OFHC-Cu) was included in the study to provide a baseline for comparison. The samples were exposed for 10 hours in the TGA to oxygen partial pressures ranging from 322 ppm to 1.0 atmosphere and at temperatures of up to 700 C, and examined by SEM-EDS and other techniques of metallography. This paper will summarize the results obtained.

Ogbuji, Linus U. Thomas↗

Nickel Base Superalloy Turbine Disk

A low solvus, high refractory alloy having unusually versatile processing mechanical property capabilities for advanced disks and rotors in gas turbine engines. The nickel base superalloy has a composition consisting essentially of, in weight percent, 3.0-4.0 N, 0.02-0.04 B, 0.02-0.05 C, 12.0-14.0 Cr, 19.0-22.0 Co, 2.0-3.5 Mo, greater than 1.0 to 2.1 Nb, 1.3 to 2.1 Ta,3.04.OTi,4.1 to 5.0 W, 0.03-0.06 Zr, and balance essentially Ni and incidental impurities. The superalloy combines ease of processing with high temperature capabilities to be suitable for use in various turbine engine disk, impeller, and shaft applications. The Co and Cr levels of the superalloy can provide low solvus temperature for high processing versatility. The W, Mo, Ta, and Nb refractory element levels of the superalloy can provide sustained strength, creep, and dwell crack growth resistance at high temperatures.

Gabb, Timothy P.↗

Durability Assessment of TiAl Alloys

The durability of TiAl is a prime concern for the implementation of TiAl into aerospace engines. Two durability issues, the effect of high temperature exposure on mechanical properties and impact resistance, have been investigated and the results are summarized in this paper. Exposure to elevated temperatures has been shown to be detrimental to the room temperature ductility of gamma alloys with the most likely mechanisms being the ingress of interstitials from the surface. Fluorine ion implantation has been shown to improve the oxidation resistance of gamma alloys, and ideally it could also improve the environmental embrittlement of high Nb content TiAl alloys. The effect of F ion implantation on the surface oxidation and embrittlement of a third generation, high Nb content TiAl alloy (Ti-45Al-5Nb-B-C) were investigated. Additionally, the ballistic impact resistance of a variety of gamma alloys, including Ti-48Al-2Cr- 2Nb, Ti-47Al-2Cr-2Nb, ABB-2, ABB-23, NCG359E, 95A and Ti-45Al-5Nb-B-C was accessed. Differences in the ballistic impact properties of the various alloys will be discussed, particularly with respect to their manufacturing process, microstructure, and tensile properties.

Draper, Susan L.↗

NASA Tech Briefs, July 2008

Topics covered include: Torque Sensor Based on Tunnel-Diode Oscillator; Shaft-Angle Sensor Based on Tunnel-Diode Oscillator; Ground Facility for Vicarious Calibration of Skyborne Sensors; Optical Pressure-Temperature Sensor for a Combustion Chamber; Impact-Locator Sensor Panels; Low-Loss Waveguides for Terahertz Frequencies; MEMS/ECD Method for Making Bi(2-x)Sb(x)Te3 Thermoelectric Devices; Low-Temperature Supercapacitors; Making a Back-Illuminated Imager with Back-Side Contact and Alignment Markers; Compact, Single-Stage MMIC InP HEMT Amplifier; Nb(x)Ti(1-x)N Superconducting-Nanowire Single-Photon Detectors; Improved Sand-Compaction Method for Lost-Foam Metal Casting; Improved Probe for Evaluating Compaction of Mold Sand; Polymer-Based Composite Catholytes for Li Thin-Film Cells; Using ALD To Bond CNTs to Substrates and Matrices; Alternating-Composition Layered Ceramic Barrier Coatings; Variable-Structure Control of a Model Glider Airplane; Axial Halbach Magnetic Bearings; Compact, Non-Pneumatic Rock-Powder Samplers; Biochips Containing Arrays of Carbon-Nanotube Electrodes; Nb(x)Ti(1-x)N Superconducting-Nanowire Single-Photon Detectors; Neon as a Buffer Gas for a Mercury-Ion Clock; Miniature Incandescent Lamps as Fiber-Optic Light Sources; Bidirectional Pressure-Regulator System; and Prism Window for Optical Alignment. Single-Grid-Pair Fourier Telescope for Imaging in Hard-X Rays and gamma Rays Range-Gated Metrology with Compact Optical Head Lossless, Multi-Spectral Data Compressor for Improved Compression for Pushbroom-Typetruments.

Source record↗

Flipperons for Improved Aerodynamic Performance

Lightweight, piezoelectrically actuated bending flight-control surfaces have shown promise as means of actively controlling airflows to improve the performances of transport airplanes. These bending flight-control surfaces are called flipperons because they look somewhat like small ailerons, but, unlike ailerons, are operated in an oscillatory mode reminiscent of the actions of biological flippers. The underlying concept of using flipperons and other flipperlike actuators to impart desired characteristics to flows is not new. Moreover, elements of flipperon-based active flow-control (AFC) systems for aircraft had been developed previously, but it was not until the development reported here that the elements have been integrated into a complete, controllable prototype AFC system for wind-tunnel testing to enable evaluation of the benefits of AFC for aircraft. The piezoelectric actuator materials chosen for use in the flipperons are single- crystal solid solutions of lead zinc niobate and lead titanate, denoted generically by the empirical formula (1-x)[Pb(Zn(1/3)Nb(2/3))O3]:x[PbTiO3] (where x<1) and popularly denoted by the abbreviation PZN-PT. These are relatively newly recognized piezoelectric materials that are capable of strain levels exceeding 1 percent and strain-energy densities 5 times greater than those of previously commercially available piezoelectric materials. Despite their high performance levels, (1-x)[Pb(Zn(1/3)Nb(2/3))O3]:x[PbTiO3] materials have found limited use until now because, relative to previously commercially available piezoelectric materials, they tend to be much more fragile.

Mabe, James H.↗

Universal Decoder for PPM of any Order

A recently developed algorithm for demodulation and decoding of a pulse-position- modulation (PPM) signal is suitable as a basis for designing a single hardware decoding apparatus to be capable of handling any PPM order. Hence, this algorithm offers advantages of greater flexibility and lower cost, in comparison with prior such algorithms, which necessitate the use of a distinct hardware implementation for each PPM order. In addition, in comparison with the prior algorithms, the present algorithm entails less complexity in decoding at large orders. An unavoidably lengthy presentation of background information, including definitions of terms, is prerequisite to a meaningful summary of this development. As an aid to understanding, the figure illustrates the relevant processes of coding, modulation, propagation, demodulation, and decoding. An M-ary PPM signal has M time slots per symbol period. A pulse (signifying 1) is transmitted during one of the time slots; no pulse (signifying 0) is transmitted during the other time slots. The information intended to be conveyed from the transmitting end to the receiving end of a radio or optical communication channel is a K-bit vector u. This vector is encoded by an (N,K) binary error-correcting code, producing an N-bit vector a. In turn, the vector a is subdivided into blocks of m = log2(M) bits and each such block is mapped to an M-ary PPM symbol. The resultant coding/modulation scheme can be regarded as equivalent to a nonlinear binary code. The binary vector of PPM symbols, x is transmitted over a Poisson channel, such that there is obtained, at the receiver, a Poisson-distributed photon count characterized by a mean background count nb during no-pulse time slots and a mean signal-plus-background count of ns+nb during a pulse time slot. In the receiver, demodulation of the signal is effected in an iterative soft decoding process that involves consideration of relationships among photon counts and conditional likelihoods of m-bit vectors of coded bits. Inasmuch as the likelihoods of all the m-bit vectors of coded bits mapping to the same PPM symbol are correlated, the best performance is obtained when the joint mbit conditional likelihoods are utilized. Unfortunately, the complexity of decoding, measured in the number of operations per bit, grows exponentially with m, and can thus become prohibitively expensive for large PPM orders. For a system required to handle multiple PPM orders, the cost is even higher because it is necessary to have separate decoding hardware for each order. This concludes the prerequisite background information. In the present algorithm, the decoding process as described above is modified by, among other things, introduction of an lbit marginalizer sub-algorithm. The term "l-bit marginalizer" signifies that instead of m-bit conditional likelihoods, the decoder computes l-bit conditional likelihoods, where l is fixed. Fixing l, regardless of the value of m, makes it possible to use a single hardware implementation for any PPM order. One could minimize the decoding complexity and obtain an especially simple design by fixing l at 1, but this would entail some loss of performance. An intermediate solution is to fix l at some value, greater than 1, that may be less than or greater than m. This solution makes it possible to obtain the desired flexibility to handle any PPM order while compromising between complexity and loss of performance.

Moision, Bruce E.↗

Finned Carbon-Carbon Heat Pipe with Potassium Working Fluid

This elemental space radiator heat pipe is designed to operate in the 700 to 875 K temperature range. It consists of a C-C (carbon-carbon) shell made from poly-acrylonitride fibers that are woven in an angle interlock pattern and densified with pitch at high process temperature with integrally woven fins. The fins are 2.5 cm long and 1 mm thick, and provide an extended radiating surface at the colder condenser section of the heat pipe. The weave pattern features a continuous fiber bath from the inner tube surface to the outside edges of the fins to maximize the thermal conductance, and to thus minimize the temperature drop at the condenser end. The heat pipe and radiator element together are less than one-third the mass of conventional heat pipes of the same heat rejection surface area. To prevent the molten potassium working fluid from eroding the C C heat pipe wall, the shell is lined with a thin-walled, metallic tube liner (Nb-1 wt.% Zr), which is an integral part of a hermetic metal subassembly which is furnace-brazed to the inner surface of the C-C tube. The hermetic metal liner subassembly includes end caps and fill tubes fabricated from the same Nb-1Zr alloy. A combination of laser and electron beam methods is used to weld the end caps and fill tubes. A tungsten/inert gas weld seals the fill tubes after cleaning and charging the heat pipes with potassium. The external section of this liner, which was formed by a "Uniscan" rolling process, transitions to a larger wall thickness. This section, which protrudes beyond the C-C shell, constitutes the "evaporator" part of the heat pipe, while the section inside the shell constitutes the condenser of the heat pipe (see figure).

Juhasz, Albert J.↗

Cost Estimate for Molybdenum and Tantalum Refractory Metal Alloy Flow Circuit Concepts

The Early Flight Fission-Test Facilities (EFF-TF) team at NASA Marshall Space Flight Center (MSFC) has been tasked by the Naval Reactors Prime Contract Team (NRPCT) to provide a cost and delivery rough order of magnitude estimate for a refractory metal-based lithium (Li) flow circuit. The design is based on the stainless steel Li flow circuit that is currently being assembled for an NRPCT task underway at the EFF-TF. While geometrically the flow circuit is not representative of a final flight prototype, knowledge has been gained to quantify (time and cost) the materials, manufacturing, fabrication, assembly, and operations to produce a testable configuration. This Technical Memorandum (TM) also identifies the following key issues that need to be addressed by the fabrication process: Alloy selection and forming, cost and availability, welding, bending, machining, assembly, and instrumentation. Several candidate materials were identified by NRPCT including molybdenum (Mo) alloy (Mo-47.5 %Re), tantalum (Ta) alloys (T-111, ASTAR-811C), and niobium (Nb) alloy (Nb-1 %Zr). This TM is focused only on the Mo and Ta alloys, since they are of higher concern to the ongoing effort. The initial estimate to complete a Mo-47%Re system ready for testing is =$9,000k over a period of 30 mo. The initial estimate to complete a T-111 or ASTAR-811C system ready for testing is =$12,000k over a period of 36 mo.

Hickman, Robert R.↗

Can the Lateral Proximity Effect Be Used to Create the Superconducting Transition of a Micron-Sized TES?

Recent measurements of micron-sized Mo/Au bilayer Transition Edge Sensors (TESs) have demonstrated that the TES can behave like an S-S'-S weak link due to the lateral proximity effect from superconducting leads. In this regime the Tc is a function of bias current, and the effective Tc shifts from the bilayer Tc towards the lead Tc. We explore the idea that a micron-sized S-N-S weak link could provide a new method to engineer the TES Tc. This method would be particularly useful when small size requirements for a bilayer TES (such as for a hot-electron microbolometer) lead to undesirable shifts in the bilayer Te. We present measurements of a variety of micron-sized normal Au 'TES' devices with Nb leads. We find no evidence of a superconducting transition in the Au film of these devices, in dramatic contrast to the strong lateral proximity effect seen in micron-sized Mo/Au bilayer devices. The absence of a transition in these devices is also in disagreement with theoretical predictions for S-N-S weak links. We hypothesize that a finite contact resistance between the Nb and Au may be weakening the effect. We conclude that the use of the lateral proximity effect to create a superconducting transition will be difficult given current fabrication procedures.

Barrentine, E. M.↗

Characterization of the Gaseous Companion k Andromedae B* New Keck and LBTI High-contrast Observations

Context. We previously reported the direct detection of a low mass companion at a projected separation of 55+/-2 astronomical units around the B9 type star kappa Andromedae. The properties of the system (mass ratio, separation) make it a benchmark for the understanding of the formation and evolution of gas giant planets and brown dwarfs on wide-orbits. Aims. We present new angular differential imaging (ADI) images of the system at 2.146 (K(sub s)), 3.776 (L'), 4.052 (NB 4.05) and 4.78 micrometers (M') obtained with Keck/NIRC2 and LBTI/LMIRCam, as well as more accurate near-infrared photometry of the star with the MIMIR instrument. We aim to determine the near-infrared spectral energy distribution (SED) of the companion and use it to characterize the object. Methods. We used analysis methods adapted to ADI to extract the companion flux. We compared the photometry of the object to reference young/old objects and to a set of seven PHOENIX-based atmospheric models of cool objects accounting for the formation of dust. We used evolutionary models to derive mass estimates considering a wide range of plausible initial conditions. Finally, we used dedicated formation models to discuss the possible origin of the companion. Results. We derive a more accurate J = 15.86 +/- 0.21, H = 14.95 +/- 0.13, K(sub s) = 14.32 +/- 0.09 mag for kappa And b. We redetect the companion in all our high contrast observations. We confirm previous contrasts obtained at K(sub s) and L' band. We derive NB 4.05 = 13.0 +/- 0.2 and M' = 13.3 +/- 0.3 mag and estimate Log(base 10)(L/solar luminosity) = −3.76 +/- 0.06. Atmospheric models yield T(sub eff) = 1900(+100/−200) K. They do not set constrains on the surface gravity. "Hot-start" evolutionary models predict masses of 14(+25/−2) Jupiter mass based on the luminosity and temperature estimates, and considering a conservative age range for the system (30(+120/−10) million years). "warm-start" evolutionary tracks constrain the mass to M greater than or equal to 11 Jupiter mass. Conclusions. The mass of kappa Andromedae b mostly falls in the brown-dwarf regime, due to remaining uncertainties in age and mass-luminosity models. According to the formation models, disk instability in a primordial disk could account for the position and a wide range of plausible masses of kappa and b.

spectral energy distribution (SED)↗

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗

Three-Dimensional Printing GRCop-42

GRCop-42 (Cu-4 at.% Cr-2 at.% Nb) is a copper (Cu)-chromium (Cr)-niobium (Nb) alloy that NASA developed for use in rocket propulsion components that required high thermal conductivity, excellent creep resistance, low-cycle fatigue life, and strength at elevated temperatures, such as combustion chamber liners and fuel injector face plates. Using powder bed fusion (PBF) 3D printing, NASA Marshall Space Flight Center (MSFC) and NASA Glenn Research Center (GRC) successfully printed near-fully-dense GRCop-42 components that may equal to or exceed their traditionally manufactured predecessors. This Technical Memorandum serves to summarize the process that was developed to achieve 3D printable near-fully-dense and functional GRCop-42.

Cooper, K. G.↗

Numerical Simulation of Dynamic Stall Using Near-Body Adaptive Mesh Refinement

Time-dependent Reynolds-averaged Navier-Stokes simulations have been carried out for a NACA 0012 airfoil and a flexible UH-60A rotor undergoing dynamic stall. The OVERFLOW computational fluid dynamics (CFD) code is used to explore the use of near-body adaptive mesh refinement (NB-AMR) for the first time on a flexible helicopter rotor in forward flight. Emphasis is placed on understanding the temporal and spatial convergence of the solutions, their numerical efficiency and stability, and establishing a grid-converged solution. Some of the remaining differences between CFD and flight-test measurements are discussed. Time-dependent flow visualization is used to provide an improved understanding of the physical mechanisms involved with two-dimensional and three-dimensional dynamic stall, and the NB-AMR process.

Near-Body↗

Low-Loss Microstrip Transmission Line Fabricated with Improved Liftoff Process

The µ-Spec integrated spectrometer operating at ~500 GHz, employs thin film superconducting Nb microstrip transmission lines deposited directly on a thin (450 nm) single-crystal silicon dielectric. This single-crystal silicon layer is chosen as the dielectric layer due to its low intrinsic loss, with the goal of achieving both high- efficiency and precise phase control in a compact spectrometer architecture. To avoid roughening or etching through the thin single-crystal silicon dielectric a liftoff technique was developed for patterning these microstrip transmission lines and ground plane structures. This two- layer liftoff process was designed for use with sputter deposition and resulted in a US patent. Although this original technique provided precise control of linewidth, results of initial prototype spectrometer devices and separate diagnostic co-planer waveguide resonator devices showed that unexpected loss was being introduced due to the lift-off process. This extra loss was believed to be due to the “tails” (thin tapered regions) at the edge of the metal traces resulting from the sputtering process, as well as an amorphous oxide layer at the Nb-Si interface. We have since demonstrated an improved lift-off technique, which provides a clean metal-Si interface and removes the loss-inducing tails by a two-step selective etching method. This results in a decrease in microwave loss by more than an order of magnitude when measured in co-planar waveguide microwave resonator structures. We present these microwave test results and also SEM and TEM images of the microstrip interfaces and edge profiles before and after application of the improved process.

Hess, Larry A.↗

Overview of SatCORPS Satellite-Derived Cloud and Radiation Retrieval Coverage of ARM Domains

The ARM Climate Research Facility program maintains a number of climatically representative sites, which provide long-term cloud- and climate-monitoring records via ground-based instrumentation. These measurements provide a valuable data record over a localized region, but can be greatly enhanced by use of satellite monitoring. Satellite analyses over larger domains can provide parameters helpful for monitoring climate and evaluating models. The NASA/Langley Cloud group routinely derives such cloud and radiative parameters, from various geostationary and polar-orbiting satellite coverage over ARM sites; the group provides near-realtime analyses covering the 3 ARM fixed sites, as well as the GO-Amazon AMF site. This is accomplished by employing a suite of algorithms including VISST (Visible Infrared Solar Split-Window Technique), SIST (Solar Infrared Split-Window Technique), and SINT (Solar-infrared Infrared Near-Infrared Technique), now collectively called SatCORPS (Satellite Cloud Observations and Radiative Property retrieval System). An overview and catalog of SatCORPS-derived datasets processed for ASR, and available from both the ARM archive and the NASA/Langley Cloud group website, is provided. Specific improvements included in recently added datasets such as GO-Amazon and Azores are highlighted, including an improved cloud-detection mask, as well as improvements in derived Top-of-Atmosphere (TOA) SW albedoes and LW fluxes. New narrowband-to-broadband (NB-BB) fits and corrections for improved TOA fluxes are illustrated, including MTSAT-1/CERES Aqua NB-BB fits for the TWPICE field campaign, as well as new fits covering the Azores region which incorporate GERB TOA fluxes (Geostationery Earth Radiation Budget). Finally, validation of the reprocessed SatCORPS datasets is shown.

M M Khader↗

Activity Coefficients of Siderophile Elements in Fe-Si Liquids at High Pressure

Metallic core formation in differentiated bodies in the inner solar system can takeplace between low pressures (near 1 bar) to much higher pressures (up to 100 GPa). Mostthermodynamic models of metal-silicate equilibria utilize activity coefficients for metallic tracersin Fe liquids, nearly all of which have been carried out at low pressures. This study focuses onthe effect of pressure on activity coefficients for Au, P, V, Mn, Ga, Zn, Cd, Sn, W, Pb, and Nb inliquid Fe-Si alloys. From a series of experiments at 10 GPa, 2373 K containing variable Sicontent in a metallic liquid we have derived epsilon interaction parametersin FeSi liquids (εMSi). Comparison of 1 GPa and 10 GPa data shows no difference except for Nb. Epsilonparameters derived from low pressure experiments can thus be used to calculate activitycoefficients for application to higher pressure processes (at least to 10 GPa).

K Righter↗

In-Situ Alloying of GRCop-42 via Additive Manufacturing: Precipitate Analysis

In situ alloying of elemental Cu, Cr, and Nb to form GRCop-42 (Cu-4at. % Cr-2at. % Nb)using laser powder bed fusion (LPBF) additive manufacturing (AM) was successful. Evaluation of the in situ alloyed GRCop-42(ISGRCop-42) was conducted using phase extraction to explore the effects of AM process conditions on the formation of Cr2Nb precipitates from elemental powders. It was found that ISGRCop-42successfully and repeatedly formed Cr2Nb at a yield as high as 89%of potential Cr2Nbcontent. Initial work shows that powder preparation was the most influential factor in alloying success, followed by laser power.

Additive Manufacturing↗

In-Situ Alloying of GRCop-42 via Additive Manufacturing: Precipitate Analysis

GRCop-42, a Cu-4at% Cr-2at% Nb alloy, was designed as a high temperature, high strength, high heat flux material for rocket engine combustion chamber liners by NASA Glenn Research Center. In situ alloying of GRCop-42 (ISGRCop-42) using powder bed fusion (PBF) additive manufacturing (AM) takes elemental powders of Cu, Cr, and Nb to be introduced into the PBF environment and develop the GRCop alloy while simultaneously building an AM component. Elemental powders were milled together prior to printing in an effort to facilitate the alloying process. Success of the in situ alloying process may provide lower cost, faster lead times, alloying optimization, and more design freedom in the development of regeneratively-cooled rocket propulsion systems. Evaluation of the ISGRCop-42 was conducted using a phase extraction procedure to isolate the Cr2Nb precipitates from the pure Cu matrix. The isolated precipitates were then examined using x-ray powder diffraction (XRD), scanning electron microscopy (SEM), and energy dispersion spectroscopy (EDS). It was found that ISGRCop-42 successfully and repeatedly formed Cr2Nb at a yield as high as 89% of potential Cr2Nb. Further, it was identified that the preparation of the powder was the most influential factor in alloying success, and the second most influential factor was the laser power.

In Situ alloying↗