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Status and prognosis for alternative engine materials

The current state of research and development of new materials for advanced aircraft engines is reviewed. The advantages and disadvantages of intermetallic compounds and refractory metals as replacements for today's nickel-base alloys are discussed along with some results of research directed at overcoming some of the problems which restrict their application. It is concluded that continuous fiber reinforced intermetallic matrix composites offer one of the best chances for success. However, major technical barriers still exist, especially in the development of suitable fibers. The introduction of these materials into aircraft engines is expected to take in excess of 5 to 10 years.

Stephens, Joseph R.

Quantitative ultrasonic evaluation of mechanical properties of engineering materials

Current progress in the application of ultrasonic techniques to nondestructive measurement of mechanical strength properties of engineering materials is reviewed. Even where conventional NDE techniques have shown that a part is free of overt defects, advanced NDE techniques should be available to confirm the material properties assumed in the part's design. There are many instances where metallic, composite, or ceramic parts may be free of critical defects while still being susceptible to failure under design loads due to inadequate or degraded mechanical strength. This must be considered in any failure prevention scheme that relies on fracture analysis. This review will discuss the availability of ultrasonic methods that can be applied to actual parts to assess their potential susceptibility to failure under design conditions.

Vary, A.

Durability Challenges for Next Generation of Gas Turbine Engine Materials

Aggressive fuel burn and carbon dioxide emission reduction goals for future gas turbine engines will require higher overall pressure ratio, and a significant increase in turbine inlet temperature. These goals can be achieved by increasing temperature capability of turbine engine hot section materials and decreasing weight of fan section of the engine. NASA is currently developing several advanced hot section materials for increasing temperature capability of future gas turbine engines. The materials of interest include ceramic matrix composites with 1482 - 1648 C temperature capability, advanced disk alloys with 815 C capability, and low conductivity thermal barrier coatings with erosion resistance. The presentation will provide an overview of durability challenges with emphasis on the environmental factors affecting durability for the next generation of gas turbine engine materials. The environmental factors include gaseous atmosphere in gas turbine engines, molten salt and glass deposits from airborne contaminants, impact from foreign object damage, and erosion from ingestion of small particles.

Misra, Ajay K.

National Educators' Workshop: Update 1997. Standard Experiments in Engineering Materials, Science, and Technology

This document contains a collection of experiments presented and demonstrated at the National Educators' Workshop: Update 97, held at Boeing Commercial Airplane Group, Seattle, Washington, on November 2-5, 1997. The experiments related to the nature and properties of engineering materials and provided information to assist in teaching about materials in the education community.

Gardner, James E.

National Educators' Workshop: Update 1989 Standard Experiments in Engineering Materials Science and Technology

Presented here is a collection of experiments presented and demonstrated at the National Educators' Workshop: Update 89, held October 17 to 19, 1989 at the National Aeronautics and Space Administration, Hampton, Virginia. The experiments related to the nature and properties of engineering materials and provided information to assist in teaching about materials in the education community.

Gardner, James E.

National Educators' Workshop: Update 1993. Standard Experiments in Engineering Materials Science and Technology

This document contains a collection of experiments presented and demonstrated at the National Educators' Workshop: Update 93 held at the NASA Langley Research Center in Hampton, Virginia, on November 3-5, 1993. The experiments related to the nature and properties of engineering materials and provided information to assist in teaching about materials in the education community.

Gardner, James E.

National Educators' Workshop: Update 1988. Standard Experiments in Engineering Materials Science and Technology

Presented here is a collection of experiments presented and demonstrated at the National Educators' Workshop: Update 88, held May 10 to 12, 1988 at the National Institute of Standards and Technology (NIST), Gaithersberg, Maryland. The experiments related to the nature and properties of engineering materials and provided information to assist in teaching about materials in the education community.

Gardner, James E.

Towards Integrated Computational Materials Engineering for Quantifying Performance Impacts of Microstructure and Defect Interactions in Powder Bed Fusion Parts

Powder bed fusion (PBF) additive manufacturing (AM) enables the creation of parts with complexity and functionality levels that were previously impossible with traditional manufacturing methods. By modifying the laser power, hatch spacing, or the numerous other processing parameters, the PBF process supports the production of a wide set of materials and geometries. However, that same process parameter design flexibility causes the process-design space of PBF to be massive and expensive to explore experimentally. Another challenge is quality variation across a build. As a part is being built, geometric variance between locations, such as at a thin-wall section vs. the bulk material, may cause the specified processing parameters to no longer be acceptable for producing defect-free printing. Furthermore, if the processing parameters deviate during the print process, it is difficult to assess if the part will still perform satisfactorily. Integrated Computational Materials Engineering (ICME) provides a way to understand and address these various challenges. This talk will present advancements in process-structure simulations of PBF at NASA Langley Research Center. The ability to simulate grain-scale PBF microstructures using the Physically Based Monte Carlo method will be demonstrated and compared to experimental measurements. Techniques for simulating three-dimensional lack-of-fusion and keyhole porosity defects based on the specific processing conditions and approaches for integrating the two porosity prediction techniques alongside the computational microstructure evolution models will be shown. Finally, the integration of simulated PBF microstructures, embedded process defects, and crystal plasticity finite element models to elucidate the interaction of porosity and microstructure on micromechanical fields will be demonstrated. These integrated techniques demonstrate an example of using ICME to relate processing to performance for PBF AM materials. With continued maturity, it is hoped that such ICME approaches will lead to next-generation computational-materials supported qualification and certification of AM parts.

Additive manufacturing

Materials engineering data base

The various types of materials related data that exist at the NASA Marshall Space Flight Center and compiled into databases which could be accessed by all the NASA centers and by other contractors, are presented.

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