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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

Unified constitutive model for single crystal deformation behavior with applications

Single crystal materials are being used in gas turbine airfoils and are candidates for other hot section components because of their increased temperature capabilities and resistance to thermal fatigue. Development of a constitutive model which assesses the inelastic behavior of these materials has been studied in 2 NASA programs: Life Prediction and Constitutive Models for Engine Hot Section Anisotropic Materials and Biaxial Constitutive Equation Development for Single Crystals. The model has been fit to a large body of constitutive data for single crystal PWA 1480 material. The model uses a unified approach for computing total inelastic strains (creep plus plasticity) on crystallographic slip systems reproducing observed directional and strain rate effects as a natural consequence of the summed slip system quantities. The model includes several of the effects that have been reported to influence deformation in single crystal materials, such as shear stress, latent hardening, and cross slip. The model is operational in a commercial Finite Element code and is being installed in a Boundary Element Method code.

Walker, K. P.↗
NASA NTRS1994

Magnetic properties and magnetic hardening mechansim of Pt-Co-B alloys

The intrinsic coercivity is found to be maximized in the Pt42Co45B13 ternary alloy which is undercooled and rapidly solidified (quenched using a 70 m/s wheel speed after undercooling), and then annealed (800 C for 2400 min). The same alloy, processed at slower cooling rates and annealed in the same way, has a much larger scale microstructure and a much lower resulting magnetic coercivity. The microstructure which would optimize the coercitvity of this coercivity of this ternary alloy is a completely ordered L1(sub zero) Pt-Co matrix with a submicron magnetic single-domion Co-boride precipitate. The L1(sub zero) phase is highly anistropic magnetically while the Co-boride precipate is somewhat less so. Annealing treatments designed to produced single-domain Co-boride precipitates enhance the coercivity. This suggests that the refined microstructures is responsible for the high coercivities found in the rapidly solidified and annealed alloy. The magnetic domain wall thickness for a Co-boride precipitate is determined from both experimental observation and theoretical calculation in order to evaluate its influence on the coercivity of the alloy. The effects of the pinning of domain walls and the barrier to the nucleation of reverse domains on the coercivity are discussed. Both microstrucutral analysis and theoretical calculation indicate that the high coercivities in the Pt42Co45B13 alloy are due to the difficult nucleation of reverse magnetic domains.

Qiu, Ning↗
NASA NTRS1978

Creep of oxide dispersion strengthened materials (with special reference to TD nichrome)

It was shown that the creep behavior of oxide dispersion strengthened (ODS) alloys is controlled principally by the creep properties of the matrix of the alloy devoid of particles. Thus, diffusion controlled slip process determine the rate controlling step in such materials. The role of the particles is to stabilize a fine substructure which is invariant with the creep stress over a wide range of stress. This characteristic leads to negligible strain hardening during creep and suggests that creep relations developed for pure metals and many solid solution alloys at constant structure should be used to describe the creep of ODS alloys. A second characteristics of the ODS alloys is that a stress may exist below which creep will not occur (threshold stress).

Lin, J.↗
NASA NTRS1978

Rolling element fatigue testing of gear materials

Rolling element fatigue lives of nine alloys were evaluated in Rolling Contact (RC) rigs. Test conditions included a Hertzian stress at 4,826 MPa (700 ksi), a rolling speed of 6.23 m/sec (245 in/sec.). Tests were run with a Type I oil (MIL-L-7808G) at room temperature. B-10 lives (10% failure rate) of alloys were compared versus reference alloys, VIM-VAR AISI M-50 and VAR AISI 9310. Six case carburizing alloys (AISI 9310, CBS600, CBS1000M, EX00014, Vasco X-2 and EX00053) and three through-hardening alloys (AISI M-50, VascoMax 350 and Vasco Matrix 2 evaluated, showed RCF performance inferior or equivalent to that of AISI 9310 and AISI M-50. It was also found that the effects of vacuum melting processes, different tempering temperatures, freezing cycle during heat treating, shot peening, gold plating and chrome plating employed in the present investigation did not significantly affect RCF life.

Nahm, A. H.↗
DOE OSTI2022

Phase transformation dynamics guided alloy development for additive manufacturing

Fusion-based additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the non-uniform and far-from-equilibrium heating/cooling conditions pose a significant challenge to consistently obtaining desirable phases in the as-printed parts. Here, in this study, we report a martensite stainless steel development guided by phase transformation dynamics revealed by in-situ high-speed, high-energy, high-resolution X-ray diffraction. This developed stainless steel consistently forms desired fully martensitic structure across a wide range of cooling rates (10 2 –10 7 °C/s), which enables direct printing of parts with fully martensitic structure. The as-printed material exhibits a yield strength of 1157 ± 23 MPa, comparable to its wrought counterpart after precipitation-hardening heat-treatment. The as-printed property is attributed to the fully martensitic structure and the fine precipitates formed during the intrinsic heat treatment in additive manufacturing. The phase transformation dynamics guided alloy development strategy demonstrated here opens the path for developing reliable, high-performance alloys specific for additive manufacturing.

17–4 PH stainless steel↗
NASA NTRS1992

Creep deformation of B2 aluminides

The creep resistance and elevated temperature deformation mechanisms in CoAl, FeAl, and NiAl are reviewed. The stress and temperature dependencies of the steady state creep rate, the primary creep behavior, the dislocation substructure, and the response during transient tests are used as the main indicators of the deformation processes. In single phase intermetallics, the influence of grain size, stoichiometry, and solid solution hardening have been examined. In addition, the effect of adding dispersoids, precipitates, and other types of reinforcements to improve creep strength are compared.

Nathal, M. V.↗
NASA NTRS2011

SpaceCube 2.0: An Advanced Hybrid Onboard Data Processor

The SpaceCube 2.0 is a compact, high performance, low-power onboard processing system that takes advantage of cutting-edge hybrid (CPU/FPGA/DSP) processing elements. The SpaceCube 2.0 design concept includes two commercial Virtex-5 field-programmable gate array (FPGA) parts protected by gradiation hardened by software" technology, and possesses exceptional size, weight, and power characteristics [5x5x7 in., 3.5 lb (approximately equal to 12.7 x 12.7 x 17.8 cm, 1.6 kg) 5-25 W, depending on the application fs required clock rate]. The two Virtex-5 FPGA parts are implemented in a unique back-toback configuration to maximize data transfer and computing performance. Draft computing power specifications for the SpaceCube 2.0 unit include four PowerPC 440s (1100 DMIPS each), 500+ DSP48Es (2x580 GMACS), 100+ LVDS high-speed serial I/Os (1.25 Gbps each), and 2x190 GFLOPS single-precision (65 GFLOPS double-precision) floating point performance. The SpaceCube 2.0 includes PROM memory for CPU boot, health and safety, and basic command and telemetry functionality; RAM memory for program execution; and FLASH/EEPROM memory to store algorithms and application code for the CPU, FPGA, and DSP processing elements. Program execution can be reconfigured in real time and algorithms can be updated, modified, and/or replaced at any point during the mission. Gigabit Ethernet, Spacewire, SATA and highspeed LVDS serial/parallel I/O channels are available for instrument/sensor data ingest, and mission-unique instrument interfaces can be accommodated using a compact PCI (cPCI) expansion card interface. The SpaceCube 2.0 can be utilized in NASA Earth Science, Helio/Astrophysics and Exploration missions, and Department of Defense satellites for onboard data processing. It can also be used in commercial communication and mapping satellites.

Lin, Michael↗
NASA NTRS2009

Simulating and Detecting Radiation-Induced Errors for Onboard Machine Learning

Spacecraft processors and memory are subjected to high radiation doses and therefore employ radiation-hardened components. However, these components are orders of magnitude more expensive than typical desktop components, and they lag years behind in terms of speed and size. We have integrated algorithm-based fault tolerance (ABFT) methods into onboard data analysis algorithms to detect radiation-induced errors, which ultimately may permit the use of spacecraft memory that need not be fully hardened, reducing cost and increasing capability at the same time. We have also developed a lightweight software radiation simulator, BITFLIPS, that permits evaluation of error detection strategies in a controlled fashion, including the specification of the radiation rate and selective exposure of individual data structures. Using BITFLIPS, we evaluated our error detection methods when using a support vector machine to analyze data collected by the Mars Odyssey spacecraft. We found ABFT error detection for matrix multiplication is very successful, while error detection for Gaussian kernel computation still has room for improvement.

data analysis↗
NASA NTRS1991

Creep Deformation of B2 Alumindes

The creep resistance and elevated temperature deformation mechanisms in CoAl, FeAl, and NiAl are reviewed. The stress and temperature dependencies of the steady state creep rate, the primary creep behavior, the dislocation substructure, and the response during transient tests are used as the main indicators of the deformation processes. In single phase intermetallics, the influence of grain size, stoichiometry, and solid solution hardening have been examined. In addition, the effect of adding dispersoids, precipitates, and other types of reinforcements to improve creep strength are compared.

Nathal, M. V.↗
DOE OSTI2023

Model for the Softening Factor within Stages of Work Hardening

A formulation for a dimensionless coefficient c b is derived that represents a scale of microstructural softening for alloys which follow Kocks-Mecking (K-M) work hardening behavior. The variation of the true plastic strain ε p between the proportional limit σ y and the strength σ u at the instability is determined using the Considère criterion. Parameterization of the model is limited to variables expressly measured within tensile experiments. Further development is now made for the softening factor c bi through the individual and sequential stages 3 and 4 of plastic deformation during K-M work hardening Q behavior. Application is shown for tensile test results of Ti-6Al-4V made by different additively manufactured (AM) processes. It is found that the variation in plastic strain as a function of c bi produces a continuous curve representative of the alloy system. The results of data analysis indicate that Θ o3 and c b3 increase, while Θ o4 and c b4 decrease, as the total plastic strain ε p increases. Furthermore, formulations derived for K-M stages 3 and 4 enable the evaluation of other material parameters such as the activation volume ν* for the onset of plastic deformation. This activation volume is found to be near constant, at a ν*-value of 0.353±0.036 nm 3 as computed using a strain-rate sensitivity of strength exponent m of 0.014, irrespective of the AM method used to produce the Ti-6Al-4V alloy.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Effect of misalignment on mechanical behavior of metals in creep

Application of the endochronic theory of viscoplasticity to creep, creep recovery, and stress relaxation at the small strain and short time range produced the following results: (1) The governing constitutive equations for constant-strain-rate stress-strain behavior, creep, creep recovery, and stress relaxation were derived by imposing appropriate constraints on the general constitutive equation of the endochronic theory. (2) A set of material constants was found which correlate strain-hardening, creep, creep recovery, and stress relaxation. (3) The theory predicts with reasonable accuracy the creep and creep recovery behaviors at short time. (4) The initial strain history prior to the creep stage affects the subsequent creep significantly. (5) A critical stress was established for creep recovery. A computer program, written for the misalignment problem is reported.

Wu, H. C.↗
NASA NTRS1986

Evaluation of transfer films of Salox M on 440C for HPOTP bearing cage applications, task 119

The objective of the task was to evaluate the suitability of a bronze-filled polytetra fluoroethylene (Salox M) as the cage material in Space Shuttle Main Engine (SSME) high pressure oxygen turbo pump (HPOTP) bearings. The role of the cage pocket material will be to provide a transferred lubricating interface at the ball-race contact region. A series of experiments was conducted which involved block-on-ring tests (the block was the polytetrafluoroethylene (PTFE) -filled material and the ring was through-hardened 440C steel) and high speed traction tests of two 440C disks with one disk rubbed with a PTFE block to generate a transfer film. Measurements included post test visual observations of the condition of the 440C, wear rate measurements of the blocks, and traction measurements between the disks. It was observed that both Salox M and glass-filled PTFE (Armalon) transferred PTFE to 440C at cryogenic temperatures. Bronze is also transferred to uncoated 440C from the Salox M. At room temperature no PTFE transfer was observed in the high speed disk tests due to severe frictional heating, although bronze transfer still occurred with the bronze-PTFE Salox M material. Since the bearing will operate at cryogenic temperature, transfer films are very probable. Salox M wore slightly, although probably tolerably, more than glass-filled PTFE against 440C. However, Salox M is clearly less abrasive to 440C than is the glass-filled material. When the surface layer of PTFE is depleted from the glass-filled material, the glass fibers tend to seriously abrade the steel. This problem does not occur with Salox M. The surface roughness studies indicate that smooth balls are quite reasonable for transfer films. No significant difference in wear rates of the candidate cage materials was observed when the 440C surface finish was increased from 0.025 micron to 0.1 micron cla. At higher levels of roughness, the wear rate increased. Two surface coatings (MoS2 and TiN) were tested. The surface coatings tended to reduce the Salox M wear rate and reduce bronze transfer. PTFE transfer at cryogenic temperatures still occurred with the surface coatings. Two cage design concepts are presented utilizing Salox M material. One design involves a metal-reinforced Salox M cage, while the second design uses Salox M inserts in a metal structure.

Barber, S. A.↗
DOE OSTI2022

Predicting extreme anisotropy and shape variations in impact testing of tantalum single crystals

We report recent Taylor cylinder impact tests carried out for Ta single crystals showed strong variations in dimensional changes for different crystallographic directions aligned with the cylindrical axis. In order to capture the effect of crystallography on the deformation characteristics and final shapes of the impacted cylinders, a single crystal material subroutine is adapted and embedded in the solid mechanics/dynamics Finite Element solver Abaqus to simulate the aforementioned single crystal Ta Taylor impact experiments. Details of the coupled model implementation, and insights on the role played by single crystal anisotropic flow on the deformation behavior across a broad range of strain rates and temperatures for different single crystal orientations are presented and discussed. We demonstrate the predictive capability of the adopted crystal plasticity model to capture the significant role played by crystal orientation-induced anisotropy, as well as strain hardening and adiabatic heating, on the dynamic deformation response of crystalline materials. This re-emphasizes the need of microstructure-aware models to improve the accuracy of simulations for high-consequence engineering design.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms

The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.

36 MATERIALS SCIENCE↗
NASA NTRS1985

An experimental study of biaxial yield in modified 9Cr-1Mo steel at room temperature

Described are two biaxial experiments which investigated yield, hardening, and flow behavior in modified 9Cr-1Mo steel at room temperature. The aim of these experiments was to determine whether the procedures recommended in NE Standard F9-5T for inelastic design analysis are applicable for this material in normalized and tempered condition. The first experiment investigated small offset yield behavior subsequent to radial preloads (sq rt of 3 sub sigma 12 = sub sigma 11) in tension-torsion stress space. The second experiment investigated yield behavior subsequent to nonradial preloads and also the time-dependent flow occurring during 0.5 hour periods at constant stress. The results of these experiments were qualitatively similar to those obtained earlier for types 304 and 316 stainless steel. Specifically, the von Mises yield criterion was found to provide a reasonable approximation of initial yield behavior. Although the subsequent yield surfaces suffered considerable distortion from their near-circular form after both radial and nonradial preloads, the hardening behavior was to the first order kinematic in nature. The strain-time data obtained during the 0.5 hr hold periods showed characteristics typical of creep curves. As in the case of earlier experiments, the high initial flow rates diminished more rapidly than would be estimated from elevated temperature data.

Ellis, J. R.↗
DOE OSTI2022

Monitoring accelerated alkali-silica reaction in concrete prisms with petrography and electrical conductivity measurements

We report deterioration of concrete due to alkali-silica reaction (ASR) involves a reaction between alkaline ions in the cement pore solution and non-crystalline silica found in many aggregates. Diagnosing and quantifying deterioration due to ASR in concrete currently requires destructive testing for microscopy examinations. In this paper, electrical conductivity is investigated qualitatively as an alternative non-destructive evaluation (NDE) method of ASR in hardened concrete. The study was performed using an unrestrained set of small concrete prism specimens made with highly reactive small aggregates, and kept in an environmental chamber according to ASTM C1293 standard. In a companion study, destructive petrography and damage rating index (DRI) assessment, and pore solution extraction and analysis were performed on the same set of accelerated ASR specimens. The results show that temporal evolution of nondestructive bulk resistivity is linearly correlated with destructive DRI score.

36 MATERIALS SCIENCE↗