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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Measuring the Wear and Abrasive Resistance of Air Plasma Sprayed Aluminum Oxide for Lunar Exploration

Lunar regolith, especially finer dust particles traveling at high velocities, can cause significant wear and abrasive damage to structural components that ensure a prolongated presence on the surface of the Moon. With the absence of an atmosphere and lower gravity than on Earth, regolith particles maintain high velocities at large distances from where they were generated, for example next to lunar landers. Wear-resistant ceramic and ceramic composite materials can improve the durability of spacecraft components during long missions on the Moon’s surface. Aluminum oxide coatings are lightweight, have multifunctional properties, and have high strength including high hardness and wear resistance. These properties can help improve the durability of structures used in space exploration. Air plasma sprayed (APS) aluminum oxide coatings have demonstrated the potential to protect critical structures. This study investigated the abrasive wear resistance of APS aluminum oxide coatings via Taber abrasion experiments. Taber abrasion offers the advantage of quantifying the abrasive wear behavior of particles with different shapes on a surface. In this work, an abrasive wheel made of silicon carbide was utilized to evaluate wear properties of specimens progressively over 5000 cycles. This experiment focused on testing two series of specimens to determine whether a bond coat composed of nickel, chromium, aluminum, and yttrium (NiCrAlY) improved the protective behavior of the APS aluminum oxide coating. The specimens varied in topcoat thickness and were made with and without an approximately 100 µm bond coat layer. The mass of the specimens was measured at 400 cycles, 800 cycles, 3800 cycles, and 5000 cycles. Increasing thickness was found to result in higher wear for samples with and without a bond coat. Increased mass loss in samples with a bond coat was observed indicating a need for further studies on the overall impact of the use of a bond coat on the protective behavior of the coatings. To continue designing wear resistant coatings for structural protection in space missions, the multifunctional properties of the APS aluminum oxide coating will be studied. Future experiments will determine whether the APS aluminum oxide coating can protect the structures from other aspects of the harsh space environment, such as extreme temperature variations and ionizing radiation.

aluminum oxide↗
NASA NTRS2003

Versatile Turbine Disk Alloy Designed and Processed for Higher Temperature Applications

Advanced turbine engine configurations using higher temperature combustor and airfoil concepts require compressor and turbine disks that can withstand temperatures higher than the 650 C typical of current engines. This requires disk alloy and processing improvements. A versatile disk alloy was needed that could be given either fine grain heat treatments for high strength and fatigue and creep resistance up to 704 C or given coarse grain heat treatments for high strength and creep and dwell crack-growth resistance at higher temperatures. This alloy could produce disks with uniform microstructures and properties, as well as with varied, optimized microstructures at disk bore and rim sections. A series of experimental disk alloys were designed and processed to give subscale disks about 13 cm in diameter and 4 cm thick. These alloys had varying levels of key elements to affect mechanical properties and change the "solvus" solution heat-treatment temperature necessary to produce coarse grain microstructures. Disks were given coarse grain heat treatments followed by rapid oil quenching and slower fan air quenching. These heat treatments were intended to simulate the cooling paths of rapidly cooled full-scale disks at the outermost rim and interior bore locations, respectively. Preliminary quench tests of tensile specimens and coin-size minidisks had indicated that alloys having high solvus temperatures were more prone to cracking during rapid quenching from coarse grain heat treatments. These findings were confirmed in the subscale disks, where such alloys did form undesirable quench cracks. Mechanical tests were performed on specimens from subscale disks given these coarse grain heat treatments, as well as on specimens given a fine grain heat treatment. Tensile, creep, and crack growth tests were performed at 704 C and higher temperatures. A versatile alloy was identified that had a low solvus temperature for resistance to quench cracking as well as an optimal combination of high levels of strengthening refractory elements that produced balanced high mechanical properties for both fine grain and coarse grain microstructures. This low-solvus, high-refractory (LSHR) alloy has been scaled-up to produce prototype full-scale turbine disks typical of regional jet turbofan engines. Disks were successfully heat treated to give uniform coarse grain and uniform fine grain microstructures. Additional disks were given a NASA dual microstructure heat treatment (DMHT) that intentionally varied the solution heat-treatment temperatures between the disk rim and bore (re f. 1). The disk rim was heated to a high enough temperature to produce a coarse grain microstructure, while the bore was maintained at a lower temperature to produce a fine grain microstructure (see the figure). This DMHT can produce optimal high strength, fatigue, and creep resistance up to 704 C in the cooler running disk bore, and high strength, creep resistance, and dwell crack growth resistance at higher temperatures for the hotter disk rim. Extensive mechanical testing is being initiated to compare the mechanical properties of the uniform and DMHT disks.

Gabb, TImothy P.↗
NASA NTRSDate not supplied

FY22 Superlightweight Aerospace Composites (SAC) Annual Review Presentation

Technology Product Capability - Superlightweight Aerospace Composites (SAC) technology aims to develop a carbon nanotube (CNT) based composite structural material with nearly double the specific strength of state-of-the-art carbon (SOA) fiber composites. The product capability offers a viable technology that can reduce overall vehicle structural mass by ~ 25 % to 50 %. Technical Capabilities (Technical Tall Poles) - High volume manufacturing of high strength CNT - Availability of CNT composite mechanical properties - Multiscale CNT composite modeling - CNT composite prototypes Exploration & Science Applicability - Availability of commercial quantities of high strength CNT enables the fabrication of high strength composites that can influence design paradigms for aerospace structures. - SAC technology will enable missions where high strength lightweight structures are needed.

Mia Siochi↗
NASA NTRS1983

Development of tough, strong, iron-base alloy for cryogenic applications

The development of an iron-base alloy that combines the normally divergent properties of high toughness and high strength at cryogenic temperatures is discussed. Specifically, alloy properties were sought which at -196 C would exhibit a fracture toughness of 220 MPa-m(1/2) with a corresponding yield strength of 1.4 GPa (200 ksi). Early work showed that high toughness could be achieved in Fe-12Ni alloys containing reactive metal additions such as Al, Nb, Ti, and V. Further research emphasized strengthening of these tough alloys by thermomechanical processing and the addition of Cu. Results showed that high strength and high toughness could be achieved in a single alloy at temperatures as low as -196 C. An alloy with composition Fe-12Ni-9.5Al-2Cu exhibited a yield strength of 1.65 GPa with a corresponding fracture toughness of 220 MPa-m(1/2) at -196 C. Strengthening due to Cu additions to the Fe-12Ni base alloys results primarily from precipitation of Cu-rich epsilon particles approximately 20 nm in diameter. Strengthening mechanisms are discussed in terms of an elastic modulus hardening model and are supported by transimission electron microscopy examinations of selected test specimens.

Stephens, J. R.↗
NASA NTRS1984

Fracture mechanics and surface chemistry investigations of environment-assisted crack growth

It is pointed out that environment-assisted subcritical crack growth in high-strength steels and other high-strength alloys (particularly in hydrogen and in hydrogenous environments) is an important technological problem of long standing. This problem is directly related to issues of structural integrity, durability, and reliability. The terms 'hydrogen embrittlement' and 'stress corrosion cracking' have been employed to describe the considered phenomenon. This paper provides a summary of contributions made during the past ten years toward the understanding of environmentally assisted crack growth. The processes involved in crack growth are examined, and details regarding crack growth and chemical reactions are discussed, taking into account crack growth in steels exposed to water/water vapor, the effect of hydrogen, reactions involving hydrogen sulfide, and aspects of fracture surface morphology and composition. Attention is also given to the modeling of crack growth response, crack growth in gas mixtures, and the interaction of solute atoms with the crack-tip stress field.

Wei, R. P.↗
NASA NTRS2020

Controlled Environmental Effects on Creep Test Data of Woven Fabric Webbings for Inflatable Space Modules

eveloping technologies for proposed lunar and Mars space exploration missions. Enhanced habitation sy g studied as potential habitats due to their inherent low mass and small launch volume. One goal of inflatable module research is quantification of the safe-life and end-of-life creep-strain spectrum. Full-scale pressurized inflatable modules are large, costly, and difficult to experimentally study. Therefore, material subcomponents are often studied as an alternative. An experimental thermally controlled long-term creep study of VectranTM webbings for application to inflatable modules is presented. Vectran fibers have high strength and low creep properties. High strength webbing materials are desirable for the load bearing restraint layer of inflatable modules because they are strong, flexible, and lightweight. Characterization of the creep behavior, safe-life, and end-of- life of webbing specimens will help quantify comparable life properties for inflatable modules. Several experimental multiple-year creep studies of webbing specimens in uncontrolled thermal environments have been conducted at NASA Langley Research Center. Experimental data obtained exhibits the classic creep-strain curve due to load, coupled with unique sinusoidal variation due to variation in temperature and humidity over daily and annual time periods. Results also have indicated that specimens fail within a year if the applied load is greater than 50 percent of the rated load. The primary goal of this study is to eliminate thermal effects from the creep data for a group of webbing specimens, and to allow uncontrolled thermal effects to influence the creep data of a second group of webbing specimens. Comparison of both sets of data will define how temperature influences creep data. A unique creep test facility was fabricated to facilitate the generation and comparison of the two sets of data. The facility consists of five creep test stands with an integrated heating and cooling system, and four creep test stands exposed to external environmental or ambient conditions. The facility contains displacement, temperature, humidity, and load sensors. Test specimens consist of one- inch wide, 48-inch long Vectran webbings rated at 12,500 pounds-per-inch. Experimental thermally controlled creep-strain data has been generated for two groups of webbing specimens. Applied load for all test stands was above 9000 lbs and greater than 50 percent of the rated load. Temperatures varied between 58˚F and 83˚F for the four test stands exposed to ambient conditions. Associated creep data exhibited the classic creep- strain profiles. The temperature was set to 72˚F for the five test stands in the controlled temperature environment. Creep data for tests with temperature control also exhibited the classic strain profiles. Data indicated that if the load is greater n thermal effects do not manifest. Therefore, creep tests with loads less than 50 percent of the rated load are planned for in the near future.

Kenner, Winfred S.↗
NASA NTRS2021

Regolith Adaptive Modification Systems (Rams) - Final Report

Establishing human habitation on the Moon or Mars requires a palette of reaction chemistries for deconstructing extraterrestrial soils to extract structural metals, fuels, and propellants, as well as consolidating the soils into load-bearing forms. This report outlines progress related to the fundamental chemistry of in-situ resource utilization that is the focus of our Regolith Adaptive Modification System (RAMS) NIAC project. The RAMS concept is a breakthrough approach for preparing surfaces for early landing sites–and subsequent settlement operations–on the Lunar and Martian surface, among others. The RAMS concept is aligned with aspirations and capabilities of planned NASA Artemis mission. The approach is predicated on the sequential delivery of microcapsules onto lunar and Martian surfaces, which upon rupture, release payloads that react with regolith to yield geopolymerized subsurface slabs and surface high-strength steel skin and anchors . Through successively more exothermic reactions, we are seeking to build subsurface geopolymer slabs and use thermite reactions to constitute micro-alloyed advanced high-strength steel (AHSS) and Ti—Al—V pads on surfaces of planetary bodies, thereby circumventing the need for energy-intensive sintering technologies. As a precursor delivery system used to constitute landingpads, RAMS can be scaled for robotic, human-class, and more prominent (i.e., Starship) landers and will be configured within pressurized delivery systems that use radio beacons to outline coordinates for precision landings. Microcapsule delivery systems are designed to impel precursors (nanothermite mixtures and organosilanes), which activate in response to stress, heat, or impact to constitute deep geopolymerized slabs and AHSS skins. Dust mitigation is accomplished by reaction/solidification chemistry that yields a subsurface slab and advanced high-strength steel skin and anchors.

2021 NIAC Phase I↗
NASA NTRS1974

High-temperature strength stability of three forms of chemically vapor deposited tungsten

Three types of CVD tungsten (fluoride-produced, chloride-produced, and a layered composite of the two-termed duplex) were evaluated to determine their high-temperature strength and microstructural stability following 5000-hr exposure to temperatures of 1540 and 1700 C. At the highest temperatures investigated (1540 and 1700 C), the tensile strengths of the two basic materials were essentially equal. At lower temperatures, chloride tungsten possessed lower yield strength but higher ultimate strength than fluoride tungsten while the behavior of the duplex material was generally intermediate. Apparent anomalies in high-temperature elongation behavior are explained on the basis of grain boundary cavity formation and recrystallization. The grain size of fluoride tungsten changed only slightly following 5000-h treatment at 1700 C. In contrast, chloride tungsten possessed both poor resistance to grain growth and an accompanying relatively high ductile-brittle transition temperature.

Bryant, W. A.↗
NASA NTRS1975

Harmonic generation at high field strengths - Frequency shifts and saturation phenomena

Optical harmonic generation and mixing in the gas phase has been proposed as a technique for the generation of coherent radiation in the vacuum ultraviolet and soft X-ray spectral region. At the high field strengths required by these processes the interaction between atoms and the electromagnetic field shows intensity-dependent resonances. In this paper we modify harmonic generation theory to include the effect of these frequency shifts. Closed-form expressions for generated dipole moment, absorption probability, and coherence length are presented. The most important consequences of frequency shifts on resonantly enhanced processes are that the pump laser must be tuned away from the small-field resonance frequency, that the conversion efficiency may saturate, and that the dispersion of the medium may change sign. As an example, the generation of 198-A radiation by a five-photon mixing process in Li(+) is considered.

Stappaerts, E. A.↗
NASA NTRS2008

Making High-Tensile-Strength Amalgam Components

Structural components made of amalgams can be made to have tensile strengths much greater than previously known to be possible. Amalgams, perhaps best known for their use in dental fillings, have several useful attributes, including room-temperature fabrication, corrosion resistance, dimensional stability, and high compressive strength. However, the range of applications of amalgams has been limited by their very small tensile strengths. Now, it has been discovered that the tensile strength of an amalgam depends critically on the sizes and shapes of the particles from which it is made and, consequently, the tensile strength can be greatly increased through suitable choice of the particles. Heretofore, the powder particles used to make amalgams have been, variously, in the form of micron-sized spheroids or flakes. The tensile reinforcement contributed by the spheroids and flakes is minimal because fracture paths simply go around these particles. However, if spheroids or flakes are replaced by strands having greater lengths, then tensile reinforcement can be increased significantly. The feasibility of this concept was shown in an experiment in which electrical copper wires, serving as demonstration substitutes for copper powder particles, were triturated with gallium by use of a mortar and pestle and the resulting amalgam was compressed into a mold. The tensile strength of the amalgam specimen was then measured and found to be greater than 10(exp 4) psi (greater than about 69 MPa). Much remains to be done to optimize the properties of amalgams for various applications through suitable choice of starting constituents and modification of the trituration and molding processes. The choice of wire size and composition are expected to be especially important. Perusal of phase diagrams of metal mixtures could give insight that would enable choices of solid and liquid metal constituents. Finally, whereas heretofore, only binary alloys have been considered for amalgams, ternary additions to liquid or solid components should be considered as means to impart desired properties to amalgams.

Grugel, Richard↗
NASA NTRS2002

Dual Microstructure Heat Treatment of a Nickel-Base Disk Alloy Assessed

Gas turbine engines for future subsonic aircraft will require nickel-base disk alloys that can be used at temperatures in excess of 1300 F. Smaller turbine engines, with higher rotational speeds, also require disk alloys with high strength. To address these challenges, NASA funded a series of disk programs in the 1990's. Under these initiatives, Honeywell and Allison focused their attention on Alloy 10, a high-strength, nickel-base disk alloy developed by Honeywell for application in the small turbine engines used in regional jet aircraft. Since tensile, creep, and fatigue properties are strongly influenced by alloy grain size, the effect of heat treatment on grain size and the attendant properties were studied in detail. It was observed that a fine grain microstructure offered the best tensile and fatigue properties, whereas a coarse grain microstructure offered the best creep resistance at high temperatures. Therefore, a disk with a dual microstructure, consisting of a fine-grained bore and a coarse-grained rim, should have a high potential for optimal performance. Under NASA's Ultra-Safe Propulsion Project and Ultra-Efficient Engine Technology (UEET) Program, a disk program was initiated at the NASA Glenn Research Center to assess the feasibility of using Alloy 10 to produce a dual-microstructure disk. The objectives of this program were twofold. First, existing dual-microstructure heat treatment (DMHT) technology would be applied and refined as necessary for Alloy 10 to yield the desired grain structure in full-scale forgings appropriate for use in regional gas turbine engines. Second, key mechanical properties from the bore and rim of a DMHT Alloy 10 disk would be measured and compared with conventional heat treatments to assess the benefits of DMHT technology. At Wyman Gordon and Honeywell, an active-cooling DMHT process was used to convert four full-scale Alloy 10 disks to a dual-grain microstructure. The resulting microstructures are illustrated in the photomicrographs. The fine grain size in the bore can be contrasted with the coarse grain size in the rim. Testing (at NASA Glenn) of coupons machined from these disks showed that the DMHT approach did indeed produce a high-strength, fatigue resistant bore and a creep-resistant rim. This combination of properties was previously unobtainable using conventional heat treatments, which produced disks with a uniform grain size. Future plans are in place to spin test a DMHT disk under the Ultra Safe Propulsion Project to assess the viability of this technology at the component level. This testing will include measurements of disk growth at a high temperature as well as the determination of burst speed at an intermediate temperature.

Gayda, John↗
NASA NTRS2015

Environmental Effects on Long Term Displacement Data of Woven Fabric Webbings Under Constant Load for Inflatable Structures

An experimental study of the effects of environmental temperature and humidity conditions on long-term creep displacement data of high strength Kevlar and VectranTM woven fabric webbings under constant load for inflatable structures is presented. The restraint layer of an inflatable structure for long-duration space exploration missions is designed to bear load and consists of an assembly of high strength webbings. Long-term creep displacement data of webbings can be utilized by designers to validate service life parameters of restraint layers of inflatable structures. Five groups of high-strength webbings were researched over a two year period. Each group had a unique webbing length, load rating, applied load, and test period. The five groups consisted of 1.) 6K Vectran webbings loaded to 49% ultimate tensile strength (UTS), 2.) 6K Vectran webbings loaded to 55% UTS, 3.) 12.5K Vectran webbings loaded to 22% UTS, 4.) 6K Kevlar webbings loaded to 40% and 43% UTS, and 5.) 6K Kevlar webbings loaded to 48% UTS. Results show that all webbing groups exhibit the initial two stages of three of a typical creep curve of an elastic material. Results also show that webbings exhibit unique local wave patterns over the duration of the test period. Data indicate that the local pattern is primarily generated by daily variations in relative humidity values within the test facility. Data indicate that after a three to six month period, where webbings reach a steady-state creep condition, an annual sinusoidal displacement pattern is exhibited, primarily due to variations in annual mean temperature values. Data indicates that variations in daily temperature values and annual mean humidity values have limited secondary effects on creep displacement behavior. Results show that webbings in groups 2 and 5 do not exhibit well defined annual displacement patterns because the magnitude of the applied loads cause large deformations, and data indicate that material yielding within a webbing tends to neutralize the annual sinusoidal displacement pattern. Study indicates that applied load, environmental effects, mechanical strength, coefficient of thermal expansion, and hygroscopic properties of webbings are fundamental requirements for quantifying accurate creep displacements and behaviors over multiple year time periods. Results from a study of the environmental effects on long-term creep displacement data of Kevlar and Vectran woven webbings are presented to increase the knowledge base of webbing materials and to enhance designs of inflatable space structures for long-duration space missions.

Kenner, WInfred S.↗
NASA NTRS1988

Soil Transport Implement

The design of the Soil Transport Implement (STI) for SKITTER is presented. The purpose of STI is to provide a protective layer of lunar soil for the lunar modules. The objective is to cover the lunar module with a layer of soil approximately two meters thick within a two week period. The amount of soil required to cover the module is roughly 77 dump truck loads or three million earth pounds. A spinning disk is employed to accomplish its task. STI is an autonomous, teleoperated system. The design incorporates the latest advances in composite materials and high strength, light weight alloys to achieve a high strength to weight ratio. The preliminary design should only be used to assess the feasibility of employing a spinning wheel as a soil transport implement. A mathematical model of the spinning wheel was used to evaluate the performance of this design.

Dixon, William↗
NASA NTRS1997

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.

Gangloff, Richard P.↗
NASA NTRSDate not supplied

Al-Cu-Zn-Mg Alloy for Additive Manufacturing by Electron Beam Deposition

The application of fusion-based additive manufacturing (AM) to aircraft structural components is limited by the lack of high-strength aluminum alloys optimized for AM processing. High strength aluminum alloys (such as 7050-T7451) are difficult to process by AM because of their solidification cracking susceptibility and loss of volatile alloying elements such as Zn and Mg. The performance of a proprietary Al-Cu-Zn-Mg alloy wire feedstock was evaluated for AM utilizing electron beam deposition. Deposit microstructure, composition, occurrence of porosity and cracking, and post-heat treatment tensile and fracture toughness were correlated with deposition parameters. Post-heat treatment strength, ductility, and fracture toughness were lower than typical values for wrought 7050-T7451, related to significant losses of Zn and Mg and to porosity. Recommendations are offered for modifications to wire feedstock composition and adjustments to deposition conditions and heat treatment to enable AM of electron beam deposited material that has strength comparable to 7050-T7451 wrought products.

Al-Cu-Zn-Mg alloy, electron beam deposition, mecha↗