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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Macro-scale Testing and Micromechanics Modeling of Fracture Behaviors for Boron Carbide Composites with Hierarchical Microstructures

With a unique combination of properties including high hardness, low density, wear and corrosion resistance, thermal stability, high neutron absorption, and semi-conductivity, boron carbide (B4C) is a candidate material for various engineering applications that involve extreme environment. The current applications of boron carbide, however, are limited by its intrinsic brittleness due to its strong covalent bonding. To toughen boron carbide, in this work hierarchical microstructure designs was used to provide multiple toughening mechanisms including crack deflection/bridging, micro-crack toughening, etc. Using field assisted sintering, B4C composites with hierarchical microstructure features including graphite platelets, micron and sub-micron sized TiB2 reinforcements were fabricated. The fracture toughness of fabricated B4C composites were previously measured at micro-scale using micro-indentation followed by post-testing microstructure inspection. However, questions including whether the fracture toughness enhancement measured at micro-scale can translate to macro-scale mechanical properties, and what are the fundamental mechanisms behind observed fracture toughness enhancement, remain to be answered. In this study, the fabricated B4C composites were tested using standardized four-point bending method to obtain fracture toughness at macro-scale. In addition, micromechanics modeling was conducted using MAC/GMC code and crack-band model to study the effect of residual stress and weak interphases on fracture behaviors of B4C composites reinforced with TiB2 particles. Through standardized four-point bending tests, fracture toughness enhancements up to 2.85, 3.32, and 3.65 MPa∙m(exp 1/2) (from 2.38 MPa∙m(exp 1/2)) were achieved for B4C composites with graphite platelets addition (micro/nano B4C), with TiB2 formation (micro B4C-TiB2), and with both graphite and TiB2 addition (micro/nano B4C-TiB2) respectively. Micromechanics modeling indicated that introduction of thermal residual stress and weak interphases caused enhanced micro-cracking behavior and resulted in the observed fracture toughness enhancement. These results furthered understanding about the mechanical behaviors at macro-scale and the mechanisms behind observed fracture toughness enhancement for B4C composites with hierarchical microstructures and can provide reference data for the future design of B4C composites with optimized microstructures for further fracture toughness enhancement.

Boron Carbide↗
NASA NTRS1995

Investigation of Advanced Processed Single-Crystal Turbine Blade Alloys

This investigation studied the influence of thermal processing and microstructure on the mechanical properties of the single-crystal, nickel-based superalloys PWA 1482 and PWA 1484. The objective of the program was to develop an improved single-crystal turbine blade alloy that is specifically tailored for use in hydrogen fueled rocket engine turbopumps. High-gradient casting, hot isostatic pressing (HIP), and alternate heat treatment (HT) processing parameters were developed to produce pore-free, eutectic-free microstructures with different (gamma)' precipitate morphologies. Test materials were cast in high thermal gradient solidification (greater than 30 C/cm (137 F/in.)) casting furnaces for reduced dendrite arm spacing, improved chemical homogeneity, and reduced interdendritic pore size. The HIP processing was conducted in 40 cm (15.7 in.) diameter production furnaces using a set of parameters selected from a trial matrix study. Metallography was conducted on test samples taken from each respective trial run to characterize the as-HIP microstructure. Post-HIP alternate HT processes were developed for each of the two alloys. The goal of the alternate HT processing was to fully solution the eutectic gamma/(gamma)' phase islands and to develop a series of modified (gamma)' morphologies for subsequent characterization testing. This was accomplished by slow cooling through the (gamma)' solvus at controlled rates to precipitate volume fractions of large (gamma)'. Post-solution alternate HT parameters were established for each alloy providing additional volume fractions of finer precipitates. Screening tests included tensile, high-cycle fatigue (HCF), smooth and notched low-cycle fatigue (LCF), creep, and fatigue crack growth evaluations performed in air and high pressure (34.5 MPa (5 ksi)) hydrogen at room and elevated temperature. Under the most severe embrittling conditions (HCF and smooth and notched LCF in 34.5 MPa (5 ksi) hydrogen at 20 C (68 F), screening test results showed increases in fatigue life typically on the order of 1OX, when compared to the current Space Shuttle Main Engine (SSME) Alternate Turbopump (AT) blade alloy (PWA 1480).

Peters, B. J.↗
NASA NTRS1985

Liquid Phase Miscibility Gap Materials

The manner in which the microstructural features of liquid-phase miscibility gap alloys develop was determined. This will allow control of the microstructures and the resultant properties of these alloys. The long-duration low gravity afforded by the shuttle will allow experiments supporting this research to be conducted with minimal interference from buoyancy effects and gravitationally driven convection currents. Ground base studies were conducted on Al-In, Cu-Pb, and Te-Tl alloys to determine the effect of cooling rate, composition, and interfacial energies on the phase separation and solidification processes that influence the development of microstructure in these alloys. Isothermal and directional cooling experiments and simulations are conducted. The ground based activities are used as a technological base from which flight experiments formulated and to which these flight experiments are compared.

Gelles, S. H.↗
NASA NTRS1986

Ultrasonic nondestructive materials characterization

A brief review of ultrasonic wave propagation in solid materials is presented with consideration of the altered behavior in anisotropic and nonlinear elastic materials in comparison with isotropic and linear elastic materials. Some experimental results are described in which ultrasonic velocity and attenuation measurements give insight into materials microstructure and associated mechanical properties. Recent developments with laser beam non-contact generation and detection of ultrasound are presented. The results of several years of experimental measurements using high-power ultrasound are discussed, which provide substantial evidence of the inability of presently accepted theories to fully explain the interaction of ultrasound with solid materials. Finally, a special synchrotron X-ray topographic system is described which affords the possibility of observing direct interaction of ultrasonic waves with the microstructural features of real crystalline solid materials for the first time.

Green, R. E., Jr.↗
NASA NTRS2024

Investigating Space Weathering of Ryugu Grains Using Electron Microscopy and X-Ray Computed Tomography

The effects of micrometeorite bombardment and solar wind ion irradiation – collectively known as space weathering – alter the microstructural, chemical, and spectral properties of airless surfaces. Characteristics of space weathering include vesiculated textures, amorphous grain rims (upper ~100 nm), and the production of Fe-bearing nanoparticles (npFe). The resulting modifications in the optical properties of the surface regolith include changes in spectral slope and overall reflectance of the surfaces as well as the attenuation of their characteristic absorption bands across VIS-NIR wavelengths. As the surface is continuously exposed to interplanetary space over time, the accrual of these features complicates the interpretation of remote sensing spectral data and the characterization of returned samples. Laboratory experiments that simulate solar wind irradiation and micrometeoroid impacts using carbonaceous analogs have revealed novel and complex microstructural and chemical changes, including the decrease in organic species concentrations and the reduction of Fe 3+ . In 2020, the Japan Aerospace Exploration Agency (JAXA)’s Hayabusa2 mission returned over 5 g of regolith particles from near- Earth C-type asteroid (162173) Ryugu – a unique opportunity to study space weathering on carbonaceous materials. Initial studies have established that the surface morphology and chemical signatures of space weathering in returned samples share characteristics with laser irradiation experiments simulating micrometeoroid bombardment, indicating that impacts are a significant space weathering mechanism operating on Ryugu. Here, we seek to improve our understanding of space weathering of carbonaceous asteroidal regolith grains by characterizing its effects directly on returned samples to determine the nature of space weathering on Ryugu. To do so, we performed coordinated analyses using electron beam techniques and X-ray computed tomography (XCT) to examine the effects of space weathering on grains returned from the surface of Ryugu by the Hayabusa2 mission.

L. E. Melendez↗
NASA NTRS2005

Wear of Selected Oxide Ceramics and Coatings

The use of oxide ceramics and coatings for moving mechanical components operating in high-temperature, oxidizing environments creates a need to define the tribological performance and durability of these materials. Results of research focusing on the wear behavior and properties of Al2O3/ZrO2 (Y2O3) eutectics and coatings under dry sliding conditions are discussed. The importance of microstructure and composition on wear properties of directionally solidified oxide eutectics is illustrated. Wear data of selected oxide-, nitride-, and carbide-based ceramics and coatings are given for temperatures up to 973K in air.

Miyoshi, K.↗
NASA NTRSDate not supplied

Metal Fused Filament Fabrication of Titanium Alloy for In Space Manufacturing

NASA is developing materials and processes for the in-space manufacturing of many items for the International Space Station (ISS) and future exploration platforms. These new manufacturing processes will require the further development of current 3D printing processes to achieve high-performance metal parts within the power and space constraints of the ISS. Manufacturing Ti-6Al-4V alloy parts with 3D printing using a metal fused filament fabrication (MF3) process is an alternative process to the Direct Metal Laser Sintering (DMLS) of the metal powders additive manufacturing process. Our initial work fabricating Ti-6Al-4V parts from Ti-6Al-4V powder-binder feedstock and processed with the MF3 process has resulted in 95-97% sintered densities. The current development work of optimized sintered properties investigates the effects of variation in sintering time, temperature, and vacuum on the sintered properties of Ti-6Al-4V MF3 printed tensile bars. Sintered properties such as density, hardness, and tensile properties were characterized followed by microstructural and chemical (O/C/N) analysis to understand the role of sintering process on the ensuing material properties. Future development of the MF3 process will also involve investigation of the effects of micro-milling the Ti-64Al-4V powder to nanometer particle sizes and the investigation of laser sintering of the 3D printed devices. This new micro-milling technique will have broad application to other areas that require particle size reduction of hard metallic materials, such as Nuclear Thermal Propulsion and other NASA technologies. Laser sintering in lieu of high temperature thermal sintering should allow for significant power reduction and improved processing speeds.

sintering, alloys, 3D printing↗
NASA NTRS1992

Melt-processing of lunar ceramics

The goal of this project is to produce useful ceramics materials from lunar resources using the by products of lunar oxygen production processes. Emphasis is being placed on both fabrication of a variety of melt-processed ceramics, and on understanding the mechanical properties of these materials. Previously, glass-ceramics were formed by casting large glass monoliths and heating these to grow small crystallites. The strengths of the resulting glass-ceramics were found to vary with the inverse square root of the crystal grain size. The highest strengths (greater than 300 MPa) were obtained with the smallest crystal sizes (less than 10 microns). During the past year, the kinetics of crystallization in simulated lunar regolith were examined in an effort to optimize the microstructure and, hence, mechanical properties of glass ceramics. The use of solar energy for melt-processing of regolith was examined, and strong (greater than 630 MPa) glass fibers were successfully produced by melt-spinning in a solar furnace. A study of the mechanical properties of simulated lunar glasses was completed during the past year. As on Earth, the presence of moisture was found to weaken simulated lunar glasses, although the effects of surface flaws was shown to outweigh the effect of atmospheric moisture on the strength of lunar glasses. The effect of atmospheric moisture on the toughness was also studied. As expected, toughness was found to increase only marginally in an anhydrous atmosphere. Finally, our efforts to involve undergraduates in the research lab fluorished this past year. Four undergraduates worked on various aspects of these projects; and two of them were co-authors on papers which we published.

Fabes, B. D.↗
NASA NTRS2004

Ceramic Interconnects with Low Sintering Temperature

Ceramic interconnects for use in solid oxide he1 cells are expected to operate between 900 to approximately 1000 C, sinter below 1400 C to allow co-firing and meet a number thermal mechanical requirements. The pervoskite type (ABO3) lanthanum chromite based materials have emerged as a leading candidate that will meet these criteria by varying the composition on the A and B sites. A need therefore exists to determine this material's temperature dependent electrical and mechanical properties with respect to these site substitutions. In this investigation oxide powders were prepared by the glycine-nitrate process. Ionic substitutions were carried out on A sites with Ca or Sr, and B sites with Co and Al, respectively. Only stoichiometric compositions were considered for the sake of stability. The powders and their ability to sinter were investigated by XRD, SEM, dilatometry and density measurements. The sintered materials were further examined by SEM, thermal expansion and electric conductivity measurements in order to elucidate the resulting microstructure, electrical and mechanical properties. In addition quantum mechanical calculations were performed to obtain insight into the effects of these dopants on the materials electronic band structure and lattice parameter.

Zhong, Zhi-Min↗
NASA NTRS2005

Characterization of Cold Sprayed CuCrAl Coated GRCop-84 Substrates for Reusable Launch Vehicles

An advanced Cu-8(at.%)Cr-4%Nb alloy developed at NASA's Glenn Research Center, and designated as GRCop-84, is currently being considered for use as combustor liners and nozzles in NASA's future generations of reusable launch vehicles (RLVs). Despite the fact that this alloy has superior mechanical and oxidation properties compared to many commercially available copper alloys, it is felt that its high temperature and environmental resistance capabilities can be further enhanced with the development and use of suitable coatings. Several coatings and processes are currently being evaluated for their suitability and future down selection. A newly developed CuCrAl has shown excellent oxidation resistance compared to current generation Cu-Cr coating alloys. Cold spray technology for depositing the CuCrAl coating on a GRCop-84 substrate is currently being developed under NASA's Next Generation Launch Technology (NGLT) Propulsion Research and Technology (PR&T) project. The microstructures, mechanical and thermophysical properties of overlay coated GRCop-84 substrates are discussed.

Raj, S . V.↗
NASA NTRS2003

The Role of Convection and Growth Competition on Phase Selection in Microgravity

For a wide range of compositions, Fe-Cr-Ni alloys can solidify by a two-step process: a metastable solid forms first, subsequently transforming into the stable solid phase. This two-step solidification produces a profoundly different microstructure, and therefore different properties, in the final solid. The delay time between the two steps of the solidification process varies from microseconds to seconds. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the MSL-1 mission and in ground based electrostatic levitation testing at NASA MSFC, we know that convection also has a significant effect on the delay time. By examining the effect of convection on delay time over a wide range of convection, for several different alloys, we can gain a better understanding and better control of the microstructural evolution and final structure of stainless steel alloys. MSFC provides ESL for ground-based testing in a low-convection state, and the numerical modeling that enables estimation of the convection levels under the different process conditions.

Source record↗
NASA NTRSDate not supplied

Investigating Space Weathering Effects on Carbonaceous Asteroids Using High-flux and Low-flux Ion Irradiation of the Murchison Meteorite

Airless planetary bodies are continuously altered by space weathering processes such as solar wind irradiation and micrometeoroid bombardment. These processes change the microstructural, chemical, and optical properties of planetary regoliths and, in turn, complicate interpretations of surface composition from remote sensing data. Previous space weathering investigations have focused primarily on lunar and ordinary chondrite materials, the latter of which have been directly linked to S-type asteroids [1]. However, relatively little is known about space weathering of primitive carbonaceous chondrites, which contain a combination of hydrous silicate and organic phases and are hypothesized to be fragments of C-complex asteroids [2]. To address this knowledge gap and maximize the science return of missions targeting C-complex asteroids (e.g., NASA OSIRIS-REx targeting Bennu and JAXA Hayabusa2 targeting Ryugu)[3-4], we examine the spectral, microstructural, and chemical effects of simulated solar wind weathering on a carbonaceous asteroid analog material. Here, we present the results from coordinated analyses of Murchison (CM2) meteorite slabs irradiated with 1 keV/amu H+ and He+ ions.

space weathering↗
NASA NTRS1977

A Directionally Solidified Iron-chromium-aluminum-tantalum Carbide Eutectic Alloy

A eutectic alloy, Fe-13.6CR-3.7Al+9TaC, was directionally solidified in a high gradient furnace, producing a microstructure of alined TaC fibers in an oxidation resistant alpha-iron matrix. Tensile and stress rupture properties, thermal cycling resistance, and microstructures were evaluated. The alloy displays at 1000 C an ultimate tensile strength of 58 MPa and a 100-hour rupture life at a stress of 21 MPa. Thermal cycling to 1100 C induces faceting in the TaC fibers.

Harf, F. H.↗
NASA NTRSDate not supplied

Unraveling Solar Wind Space Weathering of Carbon-Rich Asterods: Low-Flux VS. High-Flux Ion Irradiation of Murchison

Introduction: Space weathering processesalter the microstructural, compositional, and optical properties of airless planetary surfaces.Solar wind space weatheringforms ion-damaged rims within the outermost ~100 nm of regolith grains through atomic-displacements and implantation of energetic H+and He+ions[1]. Transmission electron microscope(TEM)studies of space weathered Itokawa and lunar olivine particles reveal predominantly nanocrystalline solar wind-damaged rims with only minor regions of amorphization[2-5]. This finding differs from laboratoryion irradiation experiments in which samples become amorphous at fluences 2-3 orders of magnitude lower than the independentlyconstrained fluences for still-crystalline natural samples [6-7].Ion flux is generally considered to have a secondaryeffectcompared to fluence in these irradiation experiments. However, solar wind irradiation of natural samples occurs at a flux that is ~4-5 orders of magnitude lower than whatisused inlaboratory simulations (e.g., [6,8-9]). Constraining how the very low ion flux of solar wind influences the microstructural, chemical, and spectral alteration of silicate minerals will improve our understanding of solar wind space weathering and aid in the analysis of returned samples from the Hayabusa2 and OSIRIS-REx missions. Here we report results from low-and high-flux ion irradiation experiments on the Murchison (CM2)meteoritewithcomparable total fluences. Methods: We performed low-flux and high-flux He+(4 keV) and H+(1 keV) irradiation experiments on separate, dry-cut Murchison slabs. Low-flux He+irradiation reached a total fluence of 2.1 x 1016ions/cm2(~400 years of exposure at Bennu) using a flux of 3.6 x 1011ions/cm2/s; low-flux H+irradiation reached a total fluence of 3.9 x 1016ions/cm2(~30 years) using a flux of 6.6 x 1011ions/cm2/s. High-flux He+irradiation reached a total fluence of 2.0 x 1016ions/cm2(~400 years)using a flux of 9.1 x 1012ions/cm2/s; high-flux H+irradiation reached a total fluence of 5.8 x 1016ions/cm2(~50 years)using flux of 8.4 x 1012ions/cm2/s. By irradiating to similar total fluences in both the low-flux and high-flux experiments, we can better isolate and evaluatethe effects of ion flux. Differences between unirradiatedand irradiated surfaces are determined using threeanalytical techniques:(1) in situX-ray photoelectron spectroscopy(XPS) reveals changes in surface chemistry,(2) visible to near-infrared spectroscopy (VNIR; 0.35-2.5 μm) highlights changes in spectraltrends, such as albedo and slope, and (3) TEM and energy-dispersive X-ray spectroscopy (EDS) identifieschanges in nanoscale structure and elemental composition within olivine and matrix electron-transparent thin sections prepared using focused ion beam scanning electron microscopy (FIB-SEM). Results and Discussion: XPS analyses of the low-fluxand high-fluxHe+-and H+-irradiated samples showa minorreduction in surface carbon contentand chemicalreduction ofFe3+to Fe2+. The latter result is consistent with the higher Fe2+/Fe3+ratios observed in phyllosilicate-rich space weathered rims of Ryugu grains [10].VNIR analyses suggest that the low-flux H+-irradiated spectrum has a slightly bluer slope (over 0.65-2.5 μm) compared to the unirradiated VNIR spectrum from [9] while the low-flux He+-irradiated spectral slope is comparable to the unirradiated surface. Both the high-flux He+-and H+-irradiated VNIR spectra exhibitslightlyhigheralbedos at shorter wavelengths relativeto their unirradiated counterparts, with He+irradiation yielding a greater change. Thus far, the low-flux He+-irradiated matrix and olivine FIBsections as well as the low-flux H+-irradiated olivine FIBsection have been examined with TEM. The surfaces of all three samplesshowless vesiculation than high-flux/high-fluenceirradiated matrix and olivine samples from [9]. The depth of phyllosilicate amorphization in thelow-fluxHe+-irradiated matrix FIBsection varieslaterally, with crystalline domains occurring as shallow as ~25 nm in some regions. Thelow-flux He+-irradiated olivine FIBsection has acontinuous,~40-90 nm thick ion-affected layer with polycrystalline and amorphous microstructures. The low-flux H+-irradiated olivine sampleexhibits a distinct, ~10-40 nm ion-affected layer whose uppermost ~20 nmin thicker regions is predominantly amorphous.Continuing to compare results from this work to those from [9] will provide a comprehensive understanding of how ion flux impacts the microstructural, chemical, and optical modification of various mineral phases and, in turn,help identify space weathering features from parent body alteration in Hayabusa2 and OSIRIS-REx returned samples.

D L Laczniak↗
NASA NTRS1976

An oxide dispersion strengthened Ni-W-Al alloy with superior high temperature strength

Oxide dispersion strengthened alloys based on the WAZ-20 nickel-base alloy were prepared by the mechanical alloying process described by Benjamin (1973), and evaluated. The results of microstructural examinations and mechanical property determinations are discussed. It is shown that WAZ-20, a high gamma-prime fraction alloy having a high gamma-prime solvus temperature, can be effectively dispersion strengthened. The strengths obtained were outstanding, especially at 1150 and 1205 C. The strength is attributed to a combination of highly alloyed matrix, elongated grain structure, and hard phase dispersion. Tensile ductility can be improved by post-recrystallization heat treatment. The new alloy shows some potential for low stress post-extrusion forming.

Glasgow, T. K.↗
NASA NTRS1978

Manufacture of astroloy turbine disk shapes by hot isostatic pressing, volume 1

The Materials in Advanced Turbine Engines project was conducted to demonstrate container technology and establish manufacturing procedures for fabricating direct Hot Isostatic Pressing (HIP) of low carbon Astroloy to ultrasonic disk shapes. The HIP processing procedures including powder manufacture and handling, container design and fabrication, and HIP consolidation techniques were established by manufacturing five HIP disks. Based upon dimensional analysis of the first three disks, container technology was refined by modifying container tooling which resulted in closer conformity of the HIP surfaces to the sonic shape. The microstructure, chemistry and mechanical properties of two HIP low carbon Astroloy disks were characterized. One disk was subjected to a ground base experimental engine test, and the results of HIP low carbon Astroloy were analyzed and compared to conventionally forged Waspaloy. The mechanical properties of direct HIP low carbon Astroloy exceeded all property goals and the objectives of reduction in material input weight and reduction in cost were achieved.

Eng, R. D.↗