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At least 361 records · Page 20

Fatigue behavior of two alloys for Space Shuttle applications

Two superalloys used extensively in the Space Shuttle main engine are Incoloy 903 and Inconel 718. The fatigue behavior of the two alloys under varying conditions is considered. Three heats of Incoloy 903 and two of Inconel 718 were used in the study. Material was tested in several conditions, including mill polish, longitudinal mill polish, transverse mill polish, chemically milled, chemically milled plus shotpeened on one side and on both sides, gas tungsten arc welded, and electron beam welded. Both round and flat tensile specimens were tested in universal test machines. It was found that surface condition influences test results. Transverse scratches resulting from polishing and rougher surfaces lower the stress at runout in relation to that obtained on longitudinally polished and/or smooth-surfaced specimens.

Adsit, N. R.↗

Benchmark notch test for life prediction

The laser Interferometric Strain Displacement Gage (ISDG) was used to measure local strains in notched Inconel 718 test bars subjected to six different load histories at 649 C (1200 F) and including effects of tensile and compressive hold periods. The measurements were compared to simplified Neuber notch analysis predictions of notch root stress and strain. The actual strains incurred at the root of a discontinuity in cyclically loaded test samples subjected to inelastic deformation at high temperature where creep deformations readily occur were determined. The steady state cyclic, stress-strain response at the root of the discontinuity was analyzed. Flat, double notched uniaxially loaded fatigue specimens manufactured from the nickel base, superalloy Inconel 718 were used. The ISDG was used to obtain cycle by cycle recordings of notch root strain during continuous and hold time cycling at 649 C. Comparisons to Neuber and finite element model analyses were made. The results obtained provide a benchmark data set in high technology design where notch fatigue life is the predominant component service life limitation.

Domas, P. A.↗

Effects of silver and group 2 fluorides addition to plasma sprayed chromium carbide high temperature solid lubricant for foil gas bearing to 650 deg C

A new self-lubricating coating composition of nickel aluminide-bonded chromium carbide formulated with silver and Group II fluorides was developed in a research program on high temperature solid lubricants. One of the proposed applications for this new coating composition is as a wide temperature spectrum solid lubricant for complaint foil gas bearings. Friction and wear properties were obtained using a foil gas bearing start/stop apparatus at temperatures from 25 to 650 C. The journals were Inconel 718. Some were coated with the plasma sprayed experimental coating, others with unmodified nickel aluminide/chromium carbide as a baseline for comparison. The addtitional components were provided to assist in achieving low friction over the temperature range of interest. Uncoated, preoxidized Inconel X-750 foil bearings were operated against these surfaces. The foils were subjected to repeated start/stop cycles under a 14-kPa (2-psi) bearing unit loading. Sliding contact occurred during lift-off and coastdown at surface velocities less than 6 m/s (3000 rpm). Testing continued until 9000 start/stop cycles were accumulated or until a rise in starting torque indicated the journal/bearing had failed. Comparison in coating performance as well as discussions of their properties and methods of application are given.

Wagner, R. C.↗

Vapor deposited emittance/catalysis coatings for superalloys in heatshield applications

Statically oxidized Inconel 617 and MA 956 superalloys were prepared with vapor deposited aluminosilicate layers and exposed to temperatures which simulated reentry conditions. The aluminosilicate layers were 1-2 microns thick. The trials consisted of exposures to 1500-2300 F heat while surface temperatures were monitored with pyrometers. Analyses were then performed of the catalytic activity, oxidation phenomena, and radiative properties after thermal cycling the specimens for 8 hr. Both alloys were found to be catalytic to the recombination processes of dissociated species in the reentry environment. The coatings reduced the catalytic activity by 40 percent for both alloys but did not change the emittance. An enhanced Cr depletion zone was detected in the Inconel samples, implying that the coating did not prevent diffusion loss of Cr. The coated MA 956, on the other hand, gained weight over the course of the trials.

Clark, R. K.↗

SSM atomic oxygen reactions on Kapton and silverized Teflon

Surface morphology studies using scanning electron microscopy on Kapton and Inconel silver coated Teflon material samples retrieved from the Solar Maximum Mission spacecraft revealed significant changes attributed to orbital atomic oxygen induced reactions. The Kapton recession observed on the aluminized Kapton material samples appeared equivalent in nature with that observed on previous Space Shuttle LEO missions. SSM Teflon taped material samples, coated on the back side with films of Inconel protected silver were observed degraded on both sides. Visibly severe reactions on the back side produced total blackening, generally restricted to areas of tape with a narrow direct view-factor of the external orbital environment. High magnification scanning electron microscope views provided evidence of near total silver reaction, flaking, and subsequent erosion of the underlying Teflon itself. Only three of the extensive S.E.M. photographs illustrating the basic reactions observed are included pending further detailed investigations.

Roger Linton↗

Composition optimization of chromium carbide based solid lubricant coatings for foil gas bearings at temperatures to 650 C

A test program to determine the optimum composition of chromium carbide based solid lubricant coatings for compliant gas bearings is described. The friction and wear properties of the coatings are evaluated using a foil gas bearing test apparatus. The various coatings were prepared by powder blending, then plasma sprayed onto Inconel 718 test journals and diamond ground to the desired coating thickness and surface finish. The journals were operated against preoxidized nickel-chromium alloy foils. The test bearings were subjected to repeated start/stop cycles under a 14 kPa (2 psi) bearing unit load. The bearings were tested for 9000 start/stop cycles or until the specimen wear reached a predetermined failure level. In general, the addition of silver and eutectic to the chromium carbide base stock significantly reduced foil wear and increased journal coating wear. The optimum coating composition, PS212 (70 wt% metal bonded Cr3C2, 15 wt% Ag, 15% BaF2/CaF2 eutectic), reduced foil wear by a factor of two and displayed coating wear well within acceptable limits. The load capacity of the bearing using the plasma-sprayed coating prior to and after a run-in period was ascertained and compared to polished Inconel 718 specimens.

Dellacorte, Christopher↗

Effects of silver and group II fluoride solid lubricant additions to plasma-sprayed chromium carbide coatings for foil gas bearings to 650 C

A new self-lubricating coating composition of nickel aluminide-bonded chromium carbide formulated with silver and Group II fluorides was developed in a research program on high temperature solid lubricants. One of the proposed applications for this new coating composition is as a wide temperature spectrum solid lubricant for complaint foil gas bearings. Friction and wear properties were obtained using a foil gas bearing start-stop apparatus at temperatures from 25 to 650 C. The journals were Inconel 748. Some were coated with the plasma sprayed experimental coating, others with unmodified nickel aluminide/chromium carbide as a baseline for comparison. The additional components were provided to assist in achieving low friction over the temperature range of interest. Uncoated, preoxidized Inconel X-750 foil bearings were operated against these surfaces. The foils were subjected to repeated start/stop cycles under a 14-kPa (2-Psi) bearing unit loading. Sliding contact occurred during lift-off and coastdown at surface velocities less than 6 m/s (3000 rPm). Testing continued until 9000 start/stop cycles were accumulated or until a rise in starting torque indicated the journal/bearing had failed. Comparison in coating performance as well as discussions of their properties and methods of application are given.

Wagner, R. C.↗

NDE detectability of fatigue-type cracks in high-strength alloys: NDI reliability assessments

This program was conducted to generate quantitative flaw detection capability data for the nondestructive evaluation (NDE) techniques typically practiced by aerospace contractors. Inconel 718 and Haynes 188 alloy test specimens containing fatigue flaws with a wide distribution of sizes were used to assess the flaw detection capabilities at a number of contractor and government facilities. During this program 85 inspection sequences were completed presenting a total of 20,994 fatigue cracks to 53 different inspectors. The inspection sequences completed included 78 liquid penetrant, 4 eddy current, and 3 ultrasonic evaluations. The results of the assessment inspections are presented and discussed. In generating the flaw detection capability data base, procedures for data collection, data analysis, and specimen care and maintenance were developed, demonstrated, and validated. The data collection procedures and methods that evolved during this program for the measurement of flaw detection capabilities and the effects of inspection variables on performance are discussed. The Inconel 718 and Haynes 188 test specimens that were used in conducting this program and the NDE assessment procedures that were demonstrated, provide NASA with the capability to accurately assess the flaw detection capabilities of specific inspection procedures being applied or proposed for use on current and future fracture control hardware program.

Christner, Brent K.↗

High performance alloy electroforming

Electroformed copper and nickel are used in structural applications for advanced propellant combustion chambers. An improved process has been developed by Bell Aerospace Textron, Inc. wherein electroformed nickel-manganese alloy has demonstrated superior mechanical and thermal stability when compared to previously reported deposits from known nickel plating processes. Solution chemistry and parametric operating procedures are now established and material property data is established for deposition of thick, large complex shapes such as the Space Shuttle Main Engine. The critical operating variables are those governing the ratio of codeposited nickel and manganese. The deposition uniformity which in turn affects the manganese concentration distribution is affected by solution resistance and geometric effects as well as solution agitation. The manganese concentration in the deposit must be between 2000 and 3000 ppm for optimum physical properties to be realized. The study also includes data regarding deposition procedures for achieving excellent bond strength at an interface with copper, nickel-manganese or INCONEL 718. Applications for this electroformed material include fabrication of complex or re-entry shapes which would be difficult or impossible to form from high strength alloys such as INCONEL 718.

Malone, G. A.↗

Hydrogen embrittlement in nickel-hydrogen cells

It was long known that many strong metals can become weakened and brittle as the result of the accumulation of hydrogen within the metal. When the metal is stretched, it does not show normal ductile properties, but fractures prematurely. This problem can occur as the result of a hydrogen evolution reaction such as corrosion or electroplating, or due to hydrogen in the environment at the metal surface. High strength alloys such as steels are especially susceptible to hydrogen embrittlement. Nickel-hydrogen cells commonly use Inconel 718 alloy for the pressure container, and this also is susceptible to hydrogen embrittlement. Metals differ in their susceptibility to embrittlement. Hydrogen embrittlement in nickel-hydrogen cells is analyzed and the reasons why it may or may not occur are discussed. Although Inconel 718 can display hydrogen embrittlement, experience has not identified any problem with nickel-hydrogen cells. No hydrogen embrittlement problem is expected with the 718 alloy pressure container used in nickel-hydrogen cells.

Gross, Sidney↗

Electrochemical impedance spectroscopy of metal alloys in the space transportation system launch environment

AC impedance measurements were performed to investigate the corrosion resistance of 18 alloys under conditions similar to the Space Transportation System (STS) launch environment. The alloys were: (1) zirconium 702; (2) Hastelloy C-22, C-276, C-4, and B-2; (3) Inconel 600 and 825; (4) Ferralium 255; (5) Inco Alloy G-3; (6) 20Cb-3; (7) SS 904L, 304LN, 316L, 317L, and 304L; (8) ES 2205; and (9) Monel 400. AC impedance data were gathered for each alloy at various immersion times in 3.55 percent NaCl-0.1N HCl. Polarization resistance values were obtained for the Nyguist plots at each immersion time using the EQUIVALENT CIRCUIT software package available with the 388 electrochemical impedance software. Hastelloy C-22 showed the highest overall values for polarization resistance while Monel 400 and Inconel 600 had the lowest overall values. There was good general correlation between the corrosion performance of the alloys at the beach corrosion testing site, and the expected rate of corrosion as predicted based on the polarization resistance values obtained. The data indicate that electrochemical impedance spectroscopy can be used to predict the corrosion performance of metal alloys.

Calle, Luz↗

Composite material systems for hydrogen management

The task of managing hydrogen entry into elevated temperature structural materials employed in turbomachinery is a critical engineering area for propulsion systems employing hydrogen or decomposable hydrocarbons as fuel. Extant structural materials, such as the Inconel series, are embrittled by the ingress of hydrogen in service, leading to a loss of endurance and general deterioration of load-bearing dependability. Although the development of hydrogen-insensitive material systems is an obvious engineering option, to date insensitive systems cannot meet the time-temperature-loading service extremes encountered. A short-term approach that is both feasible and technologically sound is the development and employment of hydrogen barrier coatings. The present project is concerned with developing, analyzing, and physically testing laminate composite hydrogen barrier systems, employing Inconel 718 as the structural material to be protected. Barrier systems will include all metallic, metallic-to-ceramic, and, eventually, metallic/ceramic composites as the lamellae. Since space propulsion implies repetitive engine firings without earth-based inspection and repair, coating durability will be closely examined, and testing regimes will include repetitive thermal cycling to simulate damage accumulation. The target accomplishments include: generation of actual hydrogen permeation data for metallic, ceramic-metallic, and hybrid metallic/ceramic composition barrier systems, practically none of which is currently extant; definition of physical damage modes imported to barrier systems due to thermal cycling, both transient temperature profiles and steady-state thermal mismatch stress states being examined as sources of damage; and computational models that incorporate general laminate schemes as described above, including manufacturing realities such as porosity, and whatever defects are introduced through service and characterized during the experimental programs.

Pangborn, R. N.↗

Promoted combustion of nine structural metals in high-pressure gaseous oxygen - A comparison of ranking methods

The 316, 321, 440C, and 17-4 PH stainless steels, as well as Inconel 600, Inconel 718, Waspaloy, Monel 400, and Al 2219, have been evaluated for relative nonflammability in a high-pressure oxygen environment with a view to the comparative advantages of four different flammability-ranking methods. The effects of changes in test pressure, sample diameter, promoter type, and sample configuration on ranking method results are evaluated; ranking methods employing velocity as the primary ranking criterion are limited by diameter effects, while those which use extinguishing pressure are nonselective for metals with similar flammabilities.

Steinberg, Theodore A.↗

Material compatibility evaluation for liquid oxygen turbopump fluid foil bearings

Three series of tests were carried out on three polymer-coated Inconel substrate materials, Teflon S, polyimide bonded graphite fluoride (PBGF), and Teflon, which are considered for use in fluid foil bearings for a liquid oxygen turbopump. All the candidate materials passed the liquid oxygen frictional heating test. During the gaseous oxygen frictional heating test, all coatings wore off before ignition occured. Both Teflon S and PBGF coated foils passed 100 start/stop cycles against chrome-plated Inconel 718 shaft in the direct foil bearing lift-off simulation test in liquid oxygen.

Stoltzfus, J. M.↗

Influence of hydrogen oxidation kinetics on hydrogen environment embrittlement

Results are presented from experiments performed to determine the roles of hydrogen absorption and hydrogen electron transfer on the susceptibility of Fe- and Ni-base alloys to ambient-temperature hydroen embrittlement. An apparent independence is noted between hydrogen environment embrittlement and internal hydrogen embrittlement. The experiments were performed on Inconel 718, Incoloy 903, and A286. The electrochemical results obtained indicate that Inconel 718 either adsorbs hydrogen more rapidly and/or the electrochemical oxidation of the adsorbed hydrogen occurred more rapidly than in the other two materials.

Walter, R. J.↗

Elastic Properties in Tension and Shear of High Strength Nonferrous Metals and Stainless Steel - Effect of Previous Deformation and Heat Treatment

A resume is given of an investigation of the influence of plastic deformation and of annealing temperature on the tensile and shear elastic properties of high strength nonferrous metals and stainless steels in the form of rods and tubes. The data were obtained from earlier technical reports and notes, and from unpublished work in this investigation. There are also included data obtained from published and unpublished work performed on an independent investigation. The rod materials, namely, nickel, monel, inconel, copper, 13:2 Cr-Ni steel, and 18:8 Cr-Ni steel, were tested in tension; 18:8 Cr-Ni steel tubes were tested in shear, and nickel, monel, aluminum-monel, and Inconel tubes were tested in both tension and shear. There are first described experiments on the relationship between hysteresis and creep, as obtained with repeated cyclic stressing of annealed stainless steel specimens over a constant load range. These tests, which preceded the measurements of elastic properties, assisted in devising the loading time schedule used in such measurements. From corrected stress-set curves are derived the five proof stresses used as indices of elastic or yield strength. From corrected stress-strain curves are derived the secant modulus and its variation with stress. The relationship between the forms of the stress-set and stress-strain curves and the values of the properties derived is discussed. Curves of variation of proof stress and modulus with prior extension, as obtained with single rod specimens, consist in wavelike basic curves with superposed oscillations due to differences of rest interval and extension spacing; the effects of these differences are studied. Oscillations of proof stress and modulus are generally opposite in manner. The use of a series of tubular specimens corresponding to different amounts of prior extension of cold reduction gave curves almost devoid of oscillation since the effects of variation of rest interval and extension spacing were removed. Comparison is also obtained between the variation of the several properties, as measured in tension and in shear. The rise of proof stress with extension is studied, and the work-hardening rates of the various metals evaluated. The ratio between the tensile and shear proof stresses for the various annealed and cold-worked tubular metals is likewise calculated. The influence of annealing or tempering temperature on the proof stresses and moduli for the cold-worked metals and for air-hardened 13:2 Cr-Ni steel is investigated. An improvement of elastic strength generally is obtained, without important loss of yield strength, by annealing at suitable temperature. The variation of the proof stress and modulus of elasticity with plastic deformation or annealing temperature is explained in terms of the relative dominance of three important factors: namely, (a) internal stress, (b) lattice-expansion or work-hardening, and (c) crystal reorientation. Effective values of Poisson's ratio were computed from tensile and shear moduli obtained on tubular specimens. The variation of Poisson's ratio with plastic deformation and annealing temperature is explained in terms of the degree of anisotropy produced by changes of (a) internal stress and (b) crystal orientation.

METALS - ELASTICITY↗

High-temperature oxidation and ignition of metals

A study of the high-temperature oxidation of several aircraft construction materials was undertaken to assess the possibility of ignition under high-temperature flight conditions.Tests have been made both in open and closed jets, and, in addition, the burning of metals has been observed under static conditions in a pressurized vessel containing either air, oxygen, or nitrogen. When heated in an atmosphere of oxygen or when heated and plunged into a supersonic airstream, titanium, iron, carbon steel, and common alloys such as 4130 were found to have spontaneous-ignition temperatures in the solid phase (below melting) and they melted rapidly while burning. Inconel, copper, 18-8 stainless steel, Monel, and aluminum could not be made to ignite spontaneously at temperatures up to melting with the equipment available. Magnesium ignited spontaneously in either type of test at temperatures just above the melting temperature.A theory for the spontaneous ignition of metals, based on the first law of thermodynamics, is presented. Good correlation was obtained between calculated spontaneous-ignition temperatures and values measured in supersonic jet tests. There appears at the present time to be no need for concern regarding the spontaneous ignition of Inconel, the stainless steels, copper, aluminum, or magnesium for ordinary supersonic airplane or missile applications where the material temperature is kept within ordinary structural limits or at least below melting. For hypersonic applications where the material is to be melted away to absorb the heat of convection, the results of the present tests do not apply sufficiently to allow a conclusion.

Hill, Paul R↗

Characterizing the fragmentation ring on witness plates

Hole-saw ring patterns on the witness plate are studied systematically. Aluminum alloy 1100 and 6061, inconel, teflon, and lead of different thicknesses were utilized for target material. The ring patterns are observed at D(sub p)/T = 1.98 to 4.02 for aluminum 1100 target, at D(sub p)/T = 1.55 to 10.51 for aluminum 6061 target, at D(sub p)/T = 4.41 to 9 98 for inconel target, at D(sub p)/T = 1.33 to 3.94 for teflon target, and at D(subp)/T = 12.5 to 20.89 for lead target. The ring diameter showed a decreasing trend when D(sub p)/T ratio increased. An analytical model is introduced. The crater distributions on the ring were investigated. The majority of the craters are in the neighborhood of 1100 micrometers to 1400 micrometers size. Many broken string like craters were observed on the ring as well as inside the ring.

Chen, Yuan-Liang A.↗