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NASA NTRS1973

Metallurgy: A compilation

A technology utilization program is presented for the dissemination of information on technological developments which have potential utility outside the aerospace and nuclear communities. Discussion is restricted to the effects of hydrogen on a variety of metal alloys, and the mechanical properties of some recently developed alloys. Hydrogen at both low and high pressure is shown to have adverse effects on alloys such as ultrahigh-strength steels, irradiated steels, columbium, inconel alloys, titanium alloys, and certain stainless steels. The mechanical and physical properties of a wide range of alloys, their performance at elevated temperatures, and some of the processes involved in their development are also considered.

Source record↗

NASA NTRS1973

Space nuclear system volume accumulator development (SNAP program)

The engineering, design, and fabrication status of the volume accumulator units to be employed in the NaK primary and secondary coolant loops of the 5-kwe reactor thermoelectric system are described. Three identical VAU's are required - two for the primary coolant loop, and one for the secondary coolant loop. The VAU's utilize nested-formed bellows as the flexing member, are hermetically sealed, provide double containment and utilize a combination of gas pressure force and bellows spring force to obtain the desired pressure regulation of the coolant loops. All parts of the VAU, except the NaK inlet tube, are to be fabricated from Inconel 718.

Whitaker, W. D.↗

NASA NTRS1973

Development of a fracture control method for composite tanks with load sharing liners

This experimental program was undertaken to establish a fracture control method for composite tanks with load sharing liners. Uniaxial specimens containing surface flaws were loaded to failure (static fractured) and cycled to failure and the results were compared with burst tests and cyclic life tests of composite tanks having surface flaws present in the load sharing metal liners. The liner materials investigated were Inconel X750 STA, 2219-T62 aluminum and cryostretched 301 stainless steel at room temperature and at 78 K (-320 F) in liquid nitrogen. Differences were observed in comparing the uniaxial and tank test results. These differences should be resolved if an adequate fracture control method is to be developed.

Bixler, W. D.↗

NASA NTRS1973

Influence of gaseous hydrogen on metals

Tensile, fracture toughness, threshold stress intensity for sustained-load crack growth, and cyclic and sustained load crack growth rate measurements were performed on a number of alloys in high-pressure hydrogen and helium environments. The results of tensile tests performed in 34.5 MN/m2 (5000 psi) hydrogen indicated that Inconel 625 was considerable embrittled at ambient temperature but was not embrittled at 144 K (-200 F). The tensile properties of AISI 321 stainless steel were slightly reduced at ambient temperature and 144 K (-200 F). The tensile properties of Ti-5Al-2.5 Sn ELI were essentially unaffected by hydrogen at 144 K (-200 F). OFHC copper was not embrittled by hydrogen at ambient temperature or at 144 K (-200 F).

Walter, R. J.↗

NASA NTRS1972

Material variability as measured by low temperature electrical resistivity.

Low temperature electrical resistivity was used to determine the material variability (1) between different manufacturers, (2) between different heats from the same manufacturer, and (3) within a given heat for Al 2024, Al-5% Mg alloys, Inconel 718, A286 stainless, and AISI 316. Generally, the coefficient of variation for solution annealed alloys ranged from 1.2 to 14% between manufacturers, 0.8 to 5.1% between heats, and 0.1 to 1.6% within a heat with stainless steels at the low ends and Al 2024 at the high ends. The variability is increased if the material is in a precipitation-hardened condition. A statistical analysis suggests that the variability within a heat is non-normal.

Clark, A. F.↗

NASA NTRS1973

Metal-metal laminar composites for high-temperature applications.

A study was conducted to obtain indications of the potentialities of laminar metal-metal composites for elevated-temperature use. Most of the composites consisted of multiple layers or laminae of tungsten alternated with laminae of Nichrome V, a ductile, weaker, but oxidation-resistant alloy. Composites with 50 vol % of each phase made from 0.0025 cm, 0.0125 cm, or 0.050 cm laminae, were tested in tension and stress rupture at temperatures of 871 and 1093 C and in impact at 23 and 524 C. A tension and a short-time stress-rupture test was conducted on specimens of 77 vol % W-Re-Hf-C/23 vol % Inconel Alloy 600 at 1093 C.

Hoffman, C. A.↗

NASA NTRS1973

Test characteristics of a welded rotor in a 36,000-rpm Lundell alternator

Two four-pole Lundell-type rotors consisting of magnetic and nonmagnetic materials were fabricated by weld-depositing Inconel 625 between two sections of AISI 4617 steel. The rotors had a major diameter of 8.28 cm (3.26 in.). Saturation curves for load and no-load conditions with one of the rotors installed in a 1200-Hz Brayton-cycle research alternator are presented. The other identical rotor was spin-tested to a speed of 63,000 rmp, which was equal to 175 percent of the rated speed.

Lumannick, S.↗

NASA NTRS1973

Flight monitor for jet engine disk cracks and the use of critical length criterion of fracture mechanics

A disk crack detector is discussed which is intended to operate under flight conditions. It monitors the disk rim for surface cracks emanating from the blade root interface. An eddy current type sensor, with a remotely located capacitance/conductance bridge and signal analyzer, can reliably detect a simulated crack 3 mm long. The sensor was tested on a spinning turbine disk at 540 C. Tests indicate that the system is useful at disk rim velocities to 460 m/sec. By using fracture mechanics, it is shown for Inconel 718 th at a crack operating under a rim stress of 34 x ten to the 7th power N/sqm has a critical length of 18 mm.

Barranger, J. P.↗

NASA NTRS1974

Strain-cycling fatigue behavior of ten structural metals tested in liquid helium (4 K), in liquid nitrogen (78 K), and in ambient air (300 K)

Strain-cycling fatigue behavior of 10 different structural alloys and metals was investigated in liquid helium (4 K), in liquid nitrogen (78 K), and in ambient air (300 K). At high cyclic lives, fatigue resistance increased with decreasing temperature for all the materials investigated. At low cyclic lives, fatigue resistance generally decreased with decreasing temperature for the materials investigated. Only for Inconel 718 did fatigue resistance increase with decreasing temperature over the entire life range investigated. Comparison of the experimental fatigue behavior with that predicted by the Manson method of universal slopes showed that the fatigue behavior of these materials can be predicted for cryogenic temperatures by using material tensile properties obtained at those same temperatures.

Nachtigall, A. J.↗

NASA NTRS1973

Impact resistance of spar-shell composite fan blades

Composite spar-shell fan blades for a 1.83 meter (6 feet) diameter fan stage were fabricated and tested in a whirling arm facility to evaluate foreign object damage (FOD) resistance. The blades were made by adhesively bonding boron-epoxy shells on titanium spars and then adhesively bonding an Inconel 625 sheath on the leading edge. The rotating blades were individually tested at a tip speed of 800 feet per second. Impacting media used were gravel, rivets, bolt, nut, ice balls, simulated birds, and a real bird. Incidence angles were typical of those which might be experienced by STOL aircraft. The tests showed that blades of the design tested in this program have satisfactory impact resistance to small objects such as gravel, rivets, nuts, bolts, and two inch diameter ice balls. The blades suffered nominal damage when impacted with one-pound birds (9 to 10 ounce slice size). However, the shell was removed from the spar for a larger slice size.

Graff, J.↗

NASA NTRS1974

Evaluation of commercially supplied silver coated Teflon for spacecraft temperature control usage

A series of tests are described which were performed to evaluate the acceptability of a commercially supplied silver backed teflon thermal control coating relative to teflon previously coated at GSFC. Optical measurements made on numerous samples indicate that the commercial material possesses an average solar absorptance of 0.085, an emittance of 0.76 and an average alpha/epsilon equal to 0.112, all of which are equivalent to the GSFC coated teflon. The emittance of the protective inconel backing was found to be 0.037. The coating is shown to have good adhesion at the Ag-teflon interface and exposure to UV irradiation uncovered no coating irregularities. Temperature cycling over the range -135 C to +200 C produced crazing in the evaporated Ag layer as expected but no delamination was observed. The suitability of Mystik no. 7366 and 3M no. 467 adhesives as bonding agents for the metallized polymer is demonstrated. Various problems associated with production reproducibility and selection of a proper bonding process are discussed.

Heaney, J. B.↗

NASA NTRS1974

Burning of solids in oxygen-rich environments in normal and reduced gravity

An experimental program was conducted to investigate the combustion characteristics of solids burning in a weightless environment. The combustion characteristics of thin cellulose acetate material were obtained from specimens burned in supercritical as well as in low pressure oxygen atmospheres. Flame spread rates were measured and found to depend on material thickness and pressure in both normal gravity (1-g) and reduced gravity (0-g). A gravity effect on the burning process was also observed; the ratio of 1-g to 0-g flame spread rate becomes larger with increasing material thickness. Qualitative results on the combustion characteristics of metal screens (stainless steel, Inconel, copper, and aluminum) burning in supercritical oxygen and normal gravity are also presented. Stainless steel (300 sq mesh) was successfully ignited in reduced gravity; no apparent difference in the flame spread pattern was observed between 1-g and 0-g.

Andracchio, C. R.↗

NASA NTRS1974

Evaluation of alloys and coatings for use in automobile thermal reactors

Several candidate alloys and coatings were evaluated for use in automobile thermal reactors. Full-size reactors of the candidate materials were evaluated in cyclic engine dynamometer tests with a peak temperature of 1040 C (1900 F). Two developmental ferritic-iron alloys, GE-1541 and NASA-18T, exhibited the best overall performance by lasting at least 60 percent of the life of test engine. Four of the alloys evaluated warrant consideration for reactor use. They are GE-1541, Armco 18 SR, NASA-18T, and Inconel 601. None of the commercial coating substrate combinations evaluated warrant consideration for reactor use.

Blankenship, C. P.↗

NASA NTRS1974

Deformation characteristics and time-dependent notch sensitivity of Udimet 700 at intermediate temperatures

Time dependent notch sensitivity was observed in Udimet 700 sheet, bar, and investment castings between 1000 and 1400 F (538 -760 C), but not at 1600 F (871 C). As was the case for modified Waspaloy, Waspaloy and Inconel 718, it occurred in notched specimens loaded below the yield strength when the creep deformation was localized. For each alloy and notched specimen geometry, a stress-average particle size zone can be defined that characterizes the notch sensitive behavior.

Wilson, D. J.↗

NASA NTRS1972

Development of a gas pressure bonded four-pole alternator rotor

Methods were developed for fabrication of a solid four pole alternator rotor by hot isostatic pressure welding. The rotor blanks welded in this program had complex geometrical mating interfaces and were of considerable bulk, being approximately 3-1/2 inches (0.089 meters) in diameter and 14 inches (0.356 meters) long. Magnetic end pieces were machined from AlSl 4340 steel, while the non-magnetic central section was of Inconel 718. Excellent welds were produced which were shown to be responsive to post weld heat treatments which substantially improved joint strength. Prior to welding the rotors, test specimens of complex geometry were welded to demonstrate that complex surfaces with intentional mechanical misfit could be readily joined using HIP welding. This preliminary work demonstrated not only that interface compliance is achieved during welding but that welding pressure is developed in these thick sections sufficient to produce sound joints. Integral weld-heat treatment cycles were developed that permitted the attainment of magnetic properties while minimizing residual stress associated with the allotropic transformation of 4340 steel.

Lessmann, G. G.↗

NASA NTRS1974

An evaluation of alloys and coatings for use in automobile thermal reactors

Several candidate alloys and coatings were evaluated for use in automobile thermal reactors. Full-size reactors of the candidate materials were analyzed in cyclic engine dynamometer tests with peak temperature of 1900 F (1040 C). Two developmental ferritic iron alloys GE1541 and NASA-18T - exhibited the best overall performance lasting at least 60% of the life of the test engine. Four of the alloys evaluated warrant consideration for reactor use. They include GE1541, Armco 18 SR, NASA-18T, and Inconel 601. None of the commercial coating substrate combinations evaluated warrant consideration for reactor use.-

Blankenship, C. P.↗

NASA NTRS1974

Study of a flight monitor for jet engine disk cracks using the critical length criterion of fracture mechanics

A disk crack detector is discussed which is intended to operate while in flight. The crack detector monitors the disk rim for radial surface cracks emanating from the blade root interface. An eddy current type sensor with a remotely located capacitance-resistance bridge and signal analyzer is able to detect reliably a simulated crack 1/8 in. long. The sensor was tested at rim velocities of 600 fps and at 1000 F. Fracture mechanics is used to calculate the critical crack length. Knowledge of the crack growth rate permits the calculation of the number of stress cycles remaining for the detected crack to grow to critical size. A plot is presented of the remaining life as a function of the critical crack length and the operating stress. It is shown that for a disk of Inconel 718 a through-the-thickness crack operating under a rim stress of 50 kpsi has a critical length of 0.7-in. and a remaining life of 130 flights.

Barranger, J. P.↗

NASA NTRS1952

Experimental Investigation of Average Heat-Transfer and Friction Coefficients for Air Flowing in Circular Tubes Having Square-Thread-Type Roughness

An investigation of forced-convection heat transfer and associated pressure drops was conducted with air flowing through electrically heated Inconel tubes having various degrees of square-thread-type roughness, an inside diameter of 1/2 inch, and a length of 24 inches. were obtained for tubes having conventional roughness ratios (height of thread/radius of tube) of 0 (smooth tube), 0.016, 0.025, and 0.037 over ranges of bulk Reynolds numbers up to 350,000, average inside-tube-wall temperatures up to 1950deg R, and heat-flux densities up to 115,000 Btu per hour per square foot. Data The experimental data showed that both heat transfer and friction increased with increase in surface roughness, becoming more pronounced with increase in Reynolds number; for a given roughness, both heat transfer and friction were also influenced by the tube wall-to-bulk temperature ratio. Good correlation of the heat-transfer data for all the tubes investigated was obtained by use of a modification of the conventional Nusselt correlation parameters wherein the mass velocity in the Reynolds number was replaced by the product of air density evaluated at the average film temperature and the so-called friction velocity; in addition, the physical properties of air were evaluated at the average film temperature. The isothermal friction data for the rough tubes, when plotted in the conventional manner, resulted in curves similar to those obtained by other investigators; that is, the curve for a given roughness breaks away from the Blasius line (representing turbulent flow in smooth tubes) at some value of Reynolds number, which decreases with increase in surface roughness, and then becomes a horizontal line (friction coefficient independent of Reynolds number). A comparison of the friction data for the rough tubes used herein indicated that the conventional roughness ratio is not an adequate measure of relative roughness for tubes having a square-thread-type element. The present data, as well as those of other investigators, were used to isolate the influence of ratios of thread height to width, thread spacing to width, and the conventional roughness ratio on the friction coefficient. A fair correlation of the friction data was obtained for each tube with heat addition when the friction coefficient and Reynolds number were defined on the basis of film properties; however, the data for each tube retained the curve characteristic of that particular roughness. The friction data for all the rough tubes could be represented by a single line for the complete turbulence region by incorporating a roughness parameter in the film correlation. No correlation was obtained for the region of incomplete turbulence.

Sams, E. W.↗