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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Fracture Analysis of Particulate Reinforced Metal Matrix Composites

A fracture analysis of highly loaded particulate reinforced composites was performed using laser moire interferometry to measure the displacements within the plastic zone at the tip of an advancing crack. Ten castings were made of five different particulate reinforcement-aluminum alloy combinations. Each casting included net-shape specimens which were used for the evaluation of fracture toughness, tensile properties, and flexure properties resulting in an extensive materials properties data. Measured fracture toughness range from 14.1 MPa for an alumina reinforced 356 aluminum alloy to 23.9 MPa for a silicon carbide reinforced 2214 aluminum alloy. For the combination of these K(sub Ic) values and the measured tensile strengths, the compact tension specimens were too thin to yield true plane strain K(sub Ic) values. All materials exhibited brittle behavior characterized by very small tensile ductility suggesting that successful application of these materials requires that the design stresses be below the elastic limit. Probabilistic design principles similar to those used with ceramics are recommended when using these materials. Such principles would include the use of experimentally determined design allowables. In the absence of thorough testing, a design allowable stress of 60 percent of the measured ultimate tensile stress is recommended.

Min, James B.↗
NASA NTRS2015

Thermoplastic Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge

Systems and methods for joining BMG Composites are disclosed. Specifically, the joining of BMG Composites is implemented so as to preserve the amorphicity of their matrix phase and the microstructure of their particulate phase. Implementation of the joining method with respect to the construction of modular cellular structures that comprise BMG Composites is also discussed.

Hofmann, Douglas C.↗
NASA NTRS2023

B 4 C-Al Metal Matrix Composites for Extreme Space Environments

Extreme space environments such as space vacuum, radiation, thermal extremes and cycles, jagged lunar dust, microgravity, micrometeoroids and orbit debris (MMOD), thrust plume ejecta, and their synergistically-adverse effects are difficult challenges for safe and sustainable space exploration to outer planets and satellites. Prolonged space radiation exposure embrittles materials and structures and abrasive jagged dust particles aggressively wear and erode moving parts leading to premature failure. To counter or even alleviate such potential failures, robust and exceptional materials are needed to make NASA missions including Artemis program sustainable with minimum service and repair needs. This study reports that boron-containing inclusion, B 4 C, can improve wear resistance and radiation shielding/resistance of aluminum alloy (Al6061) significantly to extend the service life in extreme space environments. With increasing B 4 C inclusions, the tensile strength increased up to 20 vol% at both room temperature and an elevated temperature (200˚C) while thermal conductivity decreased gradually as a function of B 4 C concentration. The neutron shielding effectiveness increased more than 110 times when 50 vol% B 4 C is incorporated in Al6061 when compared with the pristine Al6061. The shielding effectiveness under galactic cosmic rays (GCR) and solar particle events (SPE) was also studied computationally using on-line tool for the assessment of radiation in space (OLTARIS). By adding B 4 C, the adverse effect caused by secondary radiation through the Al6061 matrix was effectively suppressed to improve the shielding effectiveness against GCR and SPE. The presence of boron in B 4 C was the main reason for the enhanced radiation shielding capability against neutron, GCR, and SPE environments.

Sang-Hyon Chu↗
NASA NTRS2023

Automated Fiber Placement Through Thickness Defect Stacking Optimization

In its 2022 commercial market outlook, Boeing forecasted an 80% increase in the global fleet through 2041 compared to 2019 pre-pandemic levels. This sharp rise in demand will drive pressure onto airframe manufacturers to ramp up production and find more efficient ways to design and manufacture airplanes. Complicating this challenge is the industry’s recent transformation from traditional metal-based airframes towards hybrid composite-metal aircraft. While composites have been used in aviation for decades, aircraft manufacturers are still struggling to design and manufacture quality parts at a high rate. Automated Fiber Placement (AFP) is one of the main manufacturing techniques used to produce large-scale composite parts. After a design has been created, a manufacturing strategy has to be developed based on the working material, part geometry, and machine capabilities. This process planning stage is essential to the AFP workflow and currently requires a high level of manual input from an experienced process planner. In an effort to automate and optimize this stage, the Computer Aided Process Planning (CAPP) module was developed. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of a laminate. This Ply-Level Optimization (PLO) phase operates on the quantification of ply quality through predictable geometry-based defects such as gaps, overlaps, angle deviation, and steering. As you move from PLO to Laminate-Level Optimization (LLO) the design space grows exponentially, emphasizing the need for automated optimization. The work presented in this thesis expands CAPP’s functionality by comparing the planned fiber paths through the thickness of the laminate to mitigate stacked area defects and achieve an optimal laminate-level manufacturing strategy. Within CAPP, predicted gap and overlap defects are imported from Vericut Composites Programming (VCP) and then discretized to streamline the through-thickness comparison. Two objective functions are used to score different combinations of ply layup strategies based on defect stacking both globally and locally. Four combinatorial optimization algorithms were coupled with these objective functions to investigate the laminate-level manufacturing strategy design space and converge on the optimal plan. These algorithms were evaluated based on accuracy and efficiency through virtual testing on a complex tool surface. A separate LLO approach was developed to achieve near-optimal laminates in significantly less time. The end result is a software package which greatly reduces the required input from process planners, shortening the design-build cycle time and improving part quality.

AFP↗
DOE OSTI2024

Additive manufacturing process for producing aluminum-boron carbide metal matrix composites

A method for additive manufacturing of a composite object containing a bonded network of boron carbide particles and aluminum occupying spaces between boron carbide particles, the method comprising: (i) producing a porous preform constructed of boron carbide by an additive manufacturing process in which particles of boron carbide are bonded together; and (ii) infiltrating molten aluminum, at a temperature of 1000-1400° C., into pores of said porous preform to produce said composite object constructed of boron carbide particles within an aluminum matrix, wherein the boron carbide is present in the composite object in an amount of 30-70 wt. %. The resulting composite material is also herein described.

Cramer, Corson L.↗
NASA NTRS1980

Composites of immiscible metals

Process aids development of composites of metals that are immiscible in liquid plase. Aligned uniformly dispersed spheres or rods of bismuth in aluminum, lead in aluminum, bismuth in zinc, and other systems have been prepared. Dispersed and matrix metal are selected according to desired electrical or mechanical properties.

Johnston, M. H.↗
DOE OSTI2021

In Situ Synchrotron X-ray Micro-Diffraction Investigation of Elastic Strains in Laminated Ti-Al Composites

Spatially resolved elastic strains in the bulk interior of a laminated Ti-Al metal composite were studied during in situ tensile loading at strains up to 1.66% by a synchrotron-based micro-diffraction technique, namely differential aperture X-ray microscopy (DAXM). For both Al and Ti grains, deviatoric elastic strains were estimated based on polychromatic X-ray microbeam diffraction, while lattice strains along the normal direction of the tensile sample were directly measured using monochromatic X-ray microbeam diffraction. The estimated deviatoric strains show large spatial variations, and the mean values are consistent with the external loading conditions, i.e., increasing tensile strain along the tensile direction and increasing compressive strain along the sample normal with increasing loading. The directly measured lattice strains also show large spatial variations, although the magnitude of this variation is smaller than that for the estimated deviatoric strain. The directly measured lattice strains in Ti grains are largely consistent with the external loading, whereas those in Al grains are in contradiction with the external loading. The causes of the experimental results are discussed and related to both the laminated microstructure of the composite material and the limitations of the techniques.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Analysis of thermal mechanical fatigue in titanium matrix composites

Titanium metal matrix composites are being evaluated for structural applications on advanced hypersonic vehicles. These composites are reinforced with ceramic fibers such as silicon carbide, SCS-6. This combination of matrix and fiber results in a high stiffness, high strength composite that has good retention of properties even at elevated temperatures. However, significant thermal stresses are developed within the composite between the fiber and the matrix due to the difference in their respective coefficients of thermal expansion. In addition to the internal stresses that are generated due to thermal cycling, the overall laminate will be subjected to considerable mechanical loads during the thermal cycling. In order to develop life prediction methodology, one must be able to predict the stresses and strains that occur in the composite's constituents during the complex loading. Thus the purpose is to describe such an analytical tool, VISCOPLY.

Johnson, W. Steven↗
NASA NTRS2002

Heats of Segregation and Segregation Profiles of BCC Metals

The composition of metal alloy surfaces is often different from that of the bulk. Some alloys exhibit surface segregation, where one or more species reside preferentially at or near the surface. A detailed understanding of this behavior is necessary to correctly model such phenomena as adhesion or catalysis. Several phenomenological approaches to the problem have been put forward, falling into two broad categories: Thermodynamic approaches, where the equilibrium distribution of chemical species is computed. Atomistic approaches, where the tendency of a species to segregate is determined by computation of the energies of single atoms of that species in bulk and surface environments.

Good, Brian S.↗
DOE OSTI2025

Energy absorption of architectured PrintCast interpenetrating composites in tension

Additively manufactured (AM) metal-metal composites consisting of PrintCasted 316 L austenitic stainless-steel lattice structures infiltrated with A356 casting alloy, have recently been developed for use in high energy absorption systems with potential applications ranging from static load bearing to dynamic blast containment structures. This system has a unique mechanical behavior as the volume fraction of lattice increases showing a transition from localized to de-localized failure and dramatic increase in energy absorption capability. In this work, PrintCast A356/316 L composite tensile specimens were produced with lattice volume fractions ranging from 20 % to 50 % to capture the range of this behavior. Finite element simulations support neutron diffraction measurements of stress state. Results illustrate that in tension, the reinforcement material is in tension while the matrix support material is in compression, information offering significant insight into the transition to de-localized failure. Moreover, the simulation results provide further insight into how interfacial bonding (or lack of bonding) affects the energy absorption capabilities of the PrintCast composites.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Refractory metal composites are desirable for use in extreme environments that require materials with high specific strengths and resilience to external environments such as that found in nuclear and aerospace. However, due to the high melting temperature of refractories, liquid state joining processes such as welding remains difficult. Ultrasonic additive manufacturing (UAM) provides a potential route for processing refractory composites because it is a solid-state (i.e., no-melting) process and allows for intermittent machining operations to be performed between welds. Further, to demonstrate refractory composite fabrication, this study utilized UAM to machine a cavity to locate and sequester a Mo foil in a Zircaloy-4 (Zry-4) baseplate and additively build over the top with Zry-4 foils, thereby embedding the Mo in Zry-4 matrix. Significant deformation of the Zry-4 microstructure was observed: this deformation caused adiabatic heating and subsequent dynamic recrystallization through the transformation from α→β and then back to α as the material cooled. Flexural testing of the Zr–Mo composite revealed no delamination or failure, but the strength was not as expected, falling lower than a cold-worked Zry-4 sample. Finite element analysis supported that some bonding must have existed between the Zry-4 and Mo. There was indeed an interdiffusion zone at the Zry-4 foil–Mo foil interface, observing a metastable body-centered cubic β-Zr lathe. It was determined that sufficient strain energy was present to encourage the nucleation of the β-Zr grain along α-Zr grains. Future work is warranted to investigate UAM for refractory composite fabrication.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Composite ingot casting

A method and system for continuously or semicontinuously casting a composite metal article, such as a structurally composite ingot or the like, wherein one of the principal structural components of the ingot comprises an aluminum-lithium alloy. During such casting by a D.C. (direct chill) conventional tubular mold or electromagnetic process, the aluminum-lithium structural component of a structurally composite ingot is encircled or peripherally encased by a· further outer metal cladding component that can be cast simultaneously with the aluminum-lithium component such as another outer aluminous alloy from which lithium is absent as a constituent or impurity, although it may be present and tolerated as a trace element. In this arrangement the aluminum-lithium structural component is prevented during casting from coming into direct contact with the chilling coolant, normally water, with which lithium can react violently. Only the outer aluminous alloy envelope is subjected to the direct contact of a liquid coolant whereby as it solidifies, this outer envelope or . peripheral sheath acts as an impervious secondary mold for and protects the inner aluminum--lithium alloy structural component which is then directly controllably chilled and solidified.

George J Binczewski↗
NASA NTRS1990

Refractory metal alloys and composites for space power systems

Results are presented on recent studies of refractory-metal-alloy and refractory-metal-composite technologies for space power systems, with emphasis on work performed at the Lewis Research Center in support of the Ground Engineering System (GES) for the SP-100 reactor. Special attention is given to the mechanical properties of alloys with compositions Nb-1Zr and Nb-0.1Zr-0.1C (the PWC-11 alloy) and to advanced fiber-reinforced composites. The results to date indicate that, for the GES at a power level of about 100 kWe, the PWC-11 has attractive creep properties that will extend the capabilities of the SP-100 reactor compared to a similar system fabricated from Nb-1Zr. On the other hand, tungsten-reinforced Nb-1Zr composites were found to provide a ten-fold and four-fold creep strength over Nb-1Zr and PWC-11, respectively, at 1400 to 1500 K.

Stephens, R.↗