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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Fatigue of continuous fiber reinforced metallic materials

The complex damage mechanisms that occur in fiber reinforced advanced metallic materials are discussed. As examples, results for several layups of SCS-6/Ti-15-3 composites are presented. Fatigue tests were conducted and analyzed for both notched and unnotched specimens at room and elevated temperatures. Test conditions included isothermal, non-isothermal, and simulated mission profile thermomechanical fatigue. Test results indicated that the stress in the 0 degree fibers is the controlling factor for fatigue life for a given test condition. An effective strain approach is presented for predicting crack initiation at notches. Fiber bridging models were applied to crack growth behavior.

Johnson, W. S.↗
NASA NTRS2014

Mitigation of Crack Damage in Metallic Materials

A system designed to mitigate or heal crack damage in metallic materials has been developed where the protected material or component is coated with a low-melting temperature film. After a crack is formed, the material is heated, melting the film which then infiltrates the crack opening through capillary action. Upon solidification, the healing material inhibits further crack damage in two ways. While the crack healing material is intact, it acts like an adhesive that bonds or bridges the crack faces together. After fatigue loading damages, the healing material in the crack mouth inhibits further crack growth by creating artificially-high crack closure levels. Mechanical test data show that this method sucessfully arrests or retards crack growth in laboratory specimens.

Leser, Patrick E.↗
NASA NTRS1985

Characterization of erosion of metallic materials under cavitation attack in a mineral oil

Cavitation erosion and erosion rates of eight metallic materials representing three crystal structures were studied. The erosion experiments were conducted with a 20-kHz ultrasonic magnetostrictive oscillator in a viscous mineral oil. The erosion rates of the metals with an fcc matrix were 10 to 100 times higher than that of an hop-matrix titanium alloy. The erosion rates of iron and molybdenum, with bcc matrices, were higher than that of the titanium alloy but lower than those of those of the fcc materials. Studies with scanning electron microscopy indicated that the cavitation pits were initially formed at the grain boundaries and precipitates and that the pits formed at the junction of grain boundaries grew faster than the others. Transcrystalline craters formed by cavitation attack over the surface of grains and roughened the surfaces by multiple slip and twinning. Surface roughness measurements showed that the pits that formed over the grain boundaries deepened faster than pits. Computer analysis revealed that a geometric expression describes the nondimensional erosion curves during the time period 0.5 t (sub 0) t 2.5 t (sub 0), where t (sub 0) is the incubation period. The fcc metals had very short incubation periods; the titanium alloy had the longest incubation period.

Rao, B. C. S.↗
NASA NTRS1984

Characterization of erosion of metallic materials under cavitation attack in a mineral oil

Cavitation erosion and erosion rates of eight metallic materials representing three crystal structures were studied using a 20-kHz ultrasonic magnetostrictive oscillator in viscous mineral oil. The erosion rates of the metals with an fcc matrix were 10 to 100 times higher than that of an hcp-matrix titanium alloy. The erosion rates of iron and molybdenum, with bcc matrices, were higher than that of the titanium alloy but lower than those of the fcc metals. Scanning electron microscopy indicates that the cavitation pits are initially formed at the grain boundaries and precipitates and that the pits that formed at the triple points grew faster than the others. Transcrystalline craters formed by cavitation attack over the surface of grains and roughened the surfaces by multiple slip and twinning. Surface roughness measurements show that the pits that formed over the grain boundaries deepended faster than other pits. Computer analysis revealed that a geometric expression describes the nondimensional erosion curves during the time period 0.5 t(0) t 2.5 t(0), where t(0) is the incubation period. The fcc metals had very short incubation periods; the titanium alloy had the longest incubation period.

Rao, B. C. S.↗
NASA NTRS1985

The mechanism of erosion of metallic materials under cavitation attack

The mean depth of penetration rates (MDPRs) of eight polycrystalline metallic materials, Al 6061-T6, Cu, brass, phosphor bronze, Ni, Fe, Mo, and Ti-5Al-2.5Sn exposed to cavitation attack in a viscous mineral oil with a 20 kHz ultrasonic oscillator vibrating at 50 micron amplitude are reported. The titanium alloy followed by molybdenum have large incubation periods and small MDPRs. The incubation periods correlate linearly with the inverse of hardness and the average MDPRs correlate linearly with the inverse of tensile strength of materials. The linear relationships yield better statistical parameters than geometric and exponential relationships. The surface roughness and the ratio of pit depth to pit width (h/a) increase with the duration of cavitation attack. The ratio h/a varies from 0.1 to 0.8 for different materials. Recent investigations (20) using scanning electron microscopy to study deformation and pit formation features are briefly reviewed. Investigations with single crystals indicate that the geometry of pits and erosion are dependent on their orientation.

Rao, B. C. S.↗
DOE OSTI2020

Shear localization in metallic materials at high strain rates

Three factors govern adiabatic shear localization: strain hardening (or softening), strain-rate hardening, and thermal softening. It is typically associated with large shear strains (>1), high strain rates (10 3 –10 7 s –1 ), and high temperatures (40–100% of melting point), all of which happen within narrow regions with widths of about 1–200 μm. It is often an undesirable phenomenon, leading to failure, but there are situations where it is desirable, e. g., the generation of machining chips. Here, we review the development of both theoretical and experimental achievements, from the initiation of shear bands to their propagation with emphasis on three aspects: novel experimental techniques, novel materials, and nano/microstructural effects. The principal characteristics of adiabatic shear bands in metallic materials at the nano- and micro-scale are described. Bands that were formerly identified as transformed actually consist of nanocrystalline/ultrafine grains. These grains result from the breakup of the microstructure by a rotational recrystallization process. The evolution of the microstructure inside shear bands and their interactions for hcp, bcc, and fcc alloys, high-entropy alloys, nanocrystalline alloys, and metallic glasses are analyzed mechanistically. In conclusion, the gaps in the field and opportunities for future research are identified. Modern experimental characterization and computational techniques enable a more profound and predictive understanding of adiabatic shear localization and its avoidance in advanced materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Elaboration of Metallic Materials by SPS: Processing, Microstructures, Properties, and Shaping

After a few decades of increasing interest, spark plasma sintering (SPS) has now become a mature powder metallurgy technique, which allows assessing its performances toward fabricating enhanced materials. Here, the case of metals and alloys will be presented. The main advantage of SPS lies in its rapid heating capability enabled by the application of high intensity electric currents to a metallic powder. This presents numerous advantages balanced by some limitations that will be addressed in this review. The first section will be devoted to sintering issues, with an emphasis on the effect of the electric current on the densification mechanisms. Then, typical as-SPS microstructures and properties will be presented. In some cases, they will be compared with that of materials processed by conventional techniques. As such, examples of nanostructured materials, intermetallics, metallic glasses, and high entropy alloys, will be presented. Finally, the implementation of SPS as a technique to manufacture complex, near-net shape industrial parts will be discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Correlations between ultrasonic and fracture toughness factors in metallic materials

A heuristic mathematical basis was proposed for the experimental correlations found between ultrasonic propagation factors and fracture toughness factors in metallic materials. A crack extension model was developed wherein spontaneous stress (elastic) waves produced during microcracking are instrumental in promoting the onset of unstable crack extension. Material microstructural factors involved in the process are measurable by ultrasonic probing. Experimental results indicate that ultrasonic attenuation and velocity measurements will produce significant correlations with fracture toughness properties and also yield strength.

Vary, A.↗
NASA NTRS1978

Correlations between ultrasonic and fracture toughness factors in metallic materials

A heuristic mathematical basis is proposed for the experimental correlations found between ultrasonic propagation factors and fracture toughness factors in metallic materials. A crack extension model is proposed wherein spontaneous stress (elastic) waves produced during microcracking are instrumental in promoting the onset of unstable crack extension. Material microstructural factors involved in this process are measurable by ultrasonic probing. Experimental results indicate that ultrasonic attenuation and velocity measurements will produce significant correlations with fracture toughness properties and also yield strength.

Vary, A.↗
NASA NTRS2001

Thermal and Chemical Characterization of Non-metallic Materials Using Coupled Thermogravimetric Analysis and Infrared Spectroscopy

Thermogravimetric analysis (TGA) is widely employed in the thermal characterization of non-metallic materials, yielding valuable information on decomposition characteristics of a sample over a wide temperature range. However, a potential wealth of chemical information is lost during the process, with the evolving gases generated during thermal decomposition escaping through the exhaust line. Fourier Transform-Infrared spectroscopy (FT-IR) is a powerful analytical technique for determining many chemical constituents while in any material state, in this application, the gas phase. By linking these two techniques, evolving gases generated during the TGA process are directed into an appropriately equipped infrared spectrometer for chemical speciation. Consequently, both thermal decomposition and chemical characterization of a material may be obtained in a single sample run. In practice, a heated transfer line is employed to connect the two instruments while a purge gas stream directs the evolving gases into the FT-IR, The purge gas can be either high purity air or an inert gas such as nitrogen to allow oxidative and pyrolytic processes to be examined, respectively. The FT-IR data is collected real-time, allowing continuous monitoring of chemical compositional changes over the course of thermal decomposition. Using this coupled technique, an array of diverse materials has been examined, including composites, plastics, rubber, fiberglass epoxy resins, polycarbonates, silicones, lubricants and fluorocarbon materials. The benefit of combining these two methodologies is of particular importance in the aerospace community, where newly developing materials have little available data with which to refer. By providing both thermal and chemical data simultaneously, a more definitive and comprehensive characterization of the material is possible. Additionally, this procedure has been found to be a viable screening technique for certain materials, with the generated data useful in the selection of other appropriate analytical procedures for further material characterization.

Huff, Timothy L.↗
NASA NTRS2002

Thermal and Chemical Characterization of Non-Metallic Materials Using Coupled Thermogravimetric Analysis and Infrared Spectroscopy

Thermogravimetric analysis (TGA) is widely employed in the thermal characterization of non-metallic materials, yielding valuable information on decomposition characteristics of a sample over a wide temperature range. However, a potential wealth of chemical information is lost during the process, with the evolving gases generated during thermal decomposition escaping through the exhaust line. Fourier Transform-Infrared spectroscopy (FT-IR) is a powerful analytical technique for determining many chemical constituents while in any material state, in this application, the gas phase. By linking these two techniques, evolving gases generated during the TGA process are directed into an appropriately equipped infrared spectrometer for chemical speciation. Consequently, both thermal decomposition and chemical characterization of a material may be obtained in a single sample run. In practice, a heated transfer line is employed to connect the two instruments while a purge gas stream directs the evolving gases into the FT-IR. The purge gas can be either high purity air or an inert gas such as nitrogen to allow oxidative and pyrolytic processes to be examined, respectively. The FT-IR data is collected realtime, allowing continuous monitoring of chemical compositional changes over the course of thermal decomposition. Using this coupled technique, an array of diverse materials has been examined, including composites, plastics, rubber, fiberglass epoxy resins, polycarbonates, silicones, lubricants and fluorocarbon materials. The benefit of combining these two methodologies is of particular importance in the aerospace community, where newly developing materials have little available data with which to refer. By providing both thermal and chemical data simultaneously, a more definitive and comprehensive characterization of the material is possible. Additionally, this procedure has been found to be a viable screening technique for certain materials, with the generated data useful in the selection of other appropriate analytical procedures for further material characterization.

Huff, Timothy L.↗
DOE OSTI2025

Assessment of critical flaw sizes and crack driving forces during additive manufacturing of metallic materials

Additive manufacturing (AM) of complex engineering components is often plagued by a high susceptibility to cracking, particularly in high-strength metallic materials. While alloy design efforts have made progress in mitigating solidification defects, there remains a need for mechanistic guidelines to predict susceptibility to solid-state cracking. To address this gap, driving forces for the growth of melt pool cracks are calculated across a wide range of alloys using an efficient computational framework. Calculations are coupled with rapid single track laser experiments to elucidate trends in cracking from laser melting. The analyses conducted here highlight the important role of material properties in susceptibility to cracking, notably fracture toughness and elastic modulus. An important finding is that residual stresses that are limited in magnitude to the yield stress of the material are likely insufficient to drive cracking during cooling. Furthermore, the implications of these results are discussed in the context of alloy design for AM and residual stress accumulation during AM.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Correlations among ultrasonic propagation factors and fracture toughness properties of metallic materials

Empirical evidence was developed to show that a close relation exists among fracture toughness, yield strength, and ultrasonic attenuation properties of metallic materials. The evidence was obtained by ultrasonic probing of specimens of two maraging steels and a titanium alloy. It was concluded that nondestructive ultrasonic methods can be used to indirectly evaluate fracture-related material properties. The results suggest that these nondestructive ultrasonic measurements can also serve as an adjunct to destructive testing, measurement, and analysis of fracture properties.

Vary, A.↗
NASA NTRS1976

Correlations among ultrasonic propagation factors and fracture toughness properties of metallic materials

Empirical evidence was developed to show that a close relation exists among fracture toughness, yield strength, and ultrasonic attenuation properties of metallic materials. The evidence was obtained by ultrasonic probing of specimens of two maraging steels and a titanium alloy. It was concluded that nondestructive ultrasonic methods can be used to indirectly evaluate fracture-related material properties. The results suggest that these nondestructive ultrasonic measurements can also serve as an adjunct to destructive testing, measurement, and analysis of fracture properties.

Vary, A.↗
NASA NTRS2001

Ab-Initio Description and Prediction of Properties of Carbon-Based and Other Non-Metallic Materials

We have resolved the long-standing problem consisting of 30%-50% theoretical underestimates of the band gaps of non-metallic materials. We describe the Bagayoko, Zhao, and Williams (BZW) method that rigorously circumvents the basis-set and variational effect presumed to be a cause of these underestimates. We present ab-initio, computational results that are in agreement with experiment for diamond (C), silicon (Si), silicon carbides (3C-SiC and 4H-SiC), and other semiconductors (GaN, BaTiO3, AlN, ZnSe, ZnO). We illustrate the predictive capability of the BZW method in the case of the newly discovered cubic phase of silicon nitride (c-Si3N4) and of selected carbon nanotabes [(10,0), and (8,4)]. Our conclusion underscores the inescapable need for the BZW method in ab-initio calculations that employ a basis set in a variational approach. Current nanoscale trends amplify this need. We estimate that the potential impact of applications of the BZW method in advancing our understanding of nonmetallic materials, in informing experiment, and particularly in guiding device design and fabrication is simply priceless.

Bagayoko, D.↗
NASA NTRS1972

Metallic materials for the space shuttle.

The need for further development and reevaluation of current space-vehicle materials (intended for a single mission) to meet the long-time requirements of a space shuttle is demonstrated. Leading metallic material candidates and their properties are tabulated for a delta-wing space shuttle configuration with a metallic thermal protection system.

Tavassoli, A. A.↗