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At least 559 records · Page 31

All sources NASA NTRS DOE OSTI

NASA NTRS1972

The role of grain size and shape in strengthening of dispersion hardened nickel alloys.

Thermomechanical processing was used to develop various microstructures in Ni, Ni-2ThO2, Ni-20Cr, Ni-20Cr-2ThO2, Ni-20Cr-10W and Ni-20Cr-10W-2ThO2, and the influence of microstructure on room temperature and elevated temperature strength was investigated. The yield strength at 25 C increased with substructure refinement according to the Hall-Petch relation. It was found that substructure refinement was a much more potent means of strengthening at room temperature than was dispersion hardening. At elevated temperature (1093 C), the most important microstructural feature affecting strength of dispersion hardened nickel alloys was the grain aspect ratio, i.e. grain length, L, divided by grain width,l. The yield strength and creep strength increased linearly with increasing L/l.

Wilcox, B. A.↗

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 NTRS1975

Preparation of eutectic superalloys by EFG

An attempt was made to produce airfoil shaped bars of three different eutectic superalloys by means of the edge-defined, film-fed growth (EFG) method. The alloys used were a gamma + delta Ni-Cb alloy, a gamma/gamma prime + delta Ni-Cb-Al alloy and a Co-TaC alloy containing Ni and Cr. The development of a new die material was essential in the investigation since these alloys are reactive toward known die materials. Tantalum carbide was selected as a die material because it exhibited spontaneous capillary rise and slow rate of degradation in the liquid metals. Eutectic bars up to 1 mm thick and 6 mm wide were grown from TaC dies in order to determine the growth characteristics and the thermal gradient. Large bars of the gamma/gamma prime + delta alloy were grown and tensile tested. A die with a blind central cavity was designed and several hollow, tear-shaped bars were grown.

Hurley, G. F.↗

NASA NTRS2003

Self-Reacting Friction Stir Welding for Aluminum Complex Curvature Applications

This viewgraph representation provides an overview of sucessful research conducted by Lockheed Martin and NASA to develop an advanced self-reacting friction stir technology for complex curvature aluminum alloys. The research included weld process development for 0.320 inch Al 2219, sucessful transfer from the 'lab' scale to the production scale tool and weld quality exceeding strenght goals. This process will enable development and implementation of large scale complex geometry hardware fabrication. Topics covered include: weld process development, weld process transfer, and intermediate hardware fabrication.

Brown, Randy J.↗

NASA NTRS2004

Inspecting Friction Stir Welding using Electromagnetic Probes

A report describes the use of advanced electromagnetic probes to measure the dimensions, the spatial distribution of electrical conductivity, and related other properties of friction stir welds (FSWs) between parts made of the same or different aluminum alloy(s). The probes are of the type described in in another Tech Brief. To recapitulate: A probe of this type is essentially an eddy-current probe that includes a primary (driver) winding that meanders and multiple secondary (sensing) windings that meander along the primary winding. Electrical conductivity is commonly used as a measure of heat treatment and tempering of aluminum alloys, but prior to the development of these probes, the inadequate sensitivity and limited accuracy of electrical-conductivity probes precluded such use on FSWs between different aluminum alloys, and the resolution of those probes was inadequate for measurement of FSW dimensions with positions and metallurgical properties. In contrast, the present probes afford adequate accuracy and spatial resolution for the purposes of measuring the dimensions of FSW welds and correlating spatially varying electrical conductivities with metallurgical properties, including surface defects.

Kinchen, David G.↗

NASA NTRS1997

Structural Verification of the Space Shuttle's External Tank Super LightWeight Design: A Lesson in Innovation

The Super LightWeight Tank (SLWT) team was tasked with a daunting challenge from the outset: boost the payload capability of the Shuttle System by safely removing 7500 lbs. from the existing 65,400 lb. External Tank (ET). Tools they had to work with included a promising new Aluminum Lithium alloy, the concept of a more efficient structural configuration for the Liquid Hydrogen (LH2) tank, and a highly successful, mature Light Weight Tank (LWT) program. The 44 month schedule which the SLWT team was given for the task was ambitious by any measure. During this time the team had to not only design, build, and verify the new tank, but they also had to move a material from the early stages of development to maturity. The aluminum lithium alloy showed great promise, with an approximately 29% increase in yield strength, 15% increase in ultimate strength, 5 deg/O increase in modulus and 5 deg/O decrease in density when compared to the current 2219 alloy. But processes had to be developed and brought under control, manufacturing techniques perfected, properties characterized, and design allowable generated. Because of the schedule constraint, this material development activity had to occur in parallel with design and manufacturing. Initial design was performed using design allowable believed to be achievable with the Aluminum Lithium alloy system, but based on limited test data. Preliminary structural development tests were performed with material still in the process of iteration. This parallel path approach posed obvious challenges and risks, but also allowed a unique opportunity for interaction between the structures and materials disciplines in the formulation of the material.

Otte, Neil↗

NASA NTRS1997

Atomistic Simulations of Ti Additions to NiAl

The development of more efficient engines and power plants for future supersonic transports depends on the advancement of new high-temperature materials with temperature capabilities exceeding those of Ni-based superalloys. Having theoretical modelling techniques to aid in the design of these alloys would greatly facilitate this development. The present paper discusses a successful attempt to correlate theoretical predictions of alloy properties with experimental confirmation for ternary NiAl-Ti alloys. The B.F.S. (Bozzolo-Ferrante-Smith) method for alloys is used to predict the solubility limit and site preference energies for Ti additions of 1 to 25 at.% to NiAl. The results show the solubility limit to be around 5% Ti, above which the formation of Heusler precipitates is favored. These results were confirmed by transmission electron microscopy performed on a series of NiAl-Ti alloys.

Bozzolo, Guillermo↗

NASA NTRS1973

Modified fused silicide coatings for tantalum (Ta-10W) reentry heat shields

Results are presented of a program of research to develop a reliable, high performance, fused slurry silicide coating for the Ta-10W alloy. The effort was directed toward developing new and improved formulations for use at 2600 to 2800 F (1700 to 1811 K) in an atmospheric reentry thermal protection system with a 100-mission capability. Based on a thorough characterization of isothermal and cyclic oxidation behavior, bend transition temperatures, room- and elevated-temperature tensile properties, and creep behavior, a 2.5 Mn-33Ti-64.5Si coating (designated MTS) provides excellent protection for the Ta-10W alloy in simulated reentry environments. An extensive analysis of the oxidation behavior and characteristics of the MTS coating in terms of fundamental mechanisms also is presented.

Packer, C. M.↗

NASA NTRS1972

Further development and characterization of VM-103, a NASA wrought cobalt base alloy

The data obtained during this and previous programs indicate that the VM-103 has useful strength at temperatures as high 2200 F (1204 C), and can be considered as an alternate for other wrought superalloys such as L-605. The addition of 10 percent nickel to the standard composition improves both the hot and cold fabricability, ductility, impact strength, and metallurgical stability, while it only slightly reduces strength properties. Electroslag re-melting was effective in significantly increasing the fabricability of vacuum induction method VM-103, both with and without the 10 percent nickel addition. A specification for wrought VM-103 was developed and is included. Although thermomechanical processing improves lower temperature properties, no improvement occurs at temperatures at or above 2000 F (1093 C).

Harlow, R. A.↗

NASA NTRS1972

The role of grain size and shape in the strengthening of dispersion hardened nickel alloys

Thermomechanical processing was used to develop various microsstructures in Ni, Ni-2ThO2, Ni-20Cr, Ni-20CR-2ThO2, Ni-20Cr-10W-and Ni-20Cr-10W-2ThO2. The yield strength at 25 C increased with substructure refinement according to the Hall-Petch relation, and substructure refinement was a much more potent means of strengthening than was dispersion hardening. At elevated temperature (1093 C), the most important microstructural feature affecting strength was the grain aspect ratio (grain length, L, divided by grain width, 1. The yield strength and creep strength increased linearly with increasing L/1.

Wilcox, B. A.↗

NASA NTRS2019

Fatigue Behavior of Coated Titanium Alloys

Advanced multi-component TiAlCrTaSiN-based multilayered coatings were developed and processed onto Ti-6Al-4V (Ti-6-4) and GammaMet PX (GMPX or TiAl) alloys by a magnetron-enhanced physical vapor deposition technique. The coatings have recently been in development with the goal of improving advanced titanium alloy, turbine engine component durability and oxidation-erosion resistance. In this work, the performance of the multi-component coating system (including the outer layer nitride based coating and inner TiAlCrSi oxidation barrier bond coat) was studied, and the coating's influence on the fatigue behavior of the titanium-based alloys were compared. Although the multi-component coating was initially optimized to improve the coating's high temperature oxidation and erosion resistance, the lower ductility nitride-based coating needs further work on microstructure or composition to improve its mechanical stress resistance and strain tolerance for use in cyclically loaded, turbine blade operating conditions. This is particularly true for GMPX and other γ-TiAl alloys because these intermetallic titanium alloys have limited ductility and are very sensitive to defects such as coating cracks. However, the inner layer TiAlCrSi-coating had better adhesion and ductility, and may be a suitable choice to improve the oxidation resistance of titanium alloys.

Oxidation Barrier Coatings↗

NASA NTRS1972

Joining precipitation-hardened nickel-base alloys by friction welding

Solid state deformation welding process, friction welding, has been developed for joining precipitation hardened nickel-base alloys and other gamma prime-strengthened materials which heretofore have been virtually unweldable. Method requires rotation of one of the parts to be welded, but where applicable, it is an ideal process for high volume production jobs.

Moore, T. J.↗

NASA NTRS1991

Theoretical modelling of AFM for bimetallic tip-substrate interactions

Recently, a new technique for calculating the defect energetics of alloys based on Equivalent Crystal Theory was developed. This new technique successfully predicts the bulk properties for binary alloys as well as segregation energies in the dilute limit. The authors apply this limit for the calculation of energy and force as a function of separation of an atomic force microscope (AFM) tip and substrate. The study was done for different combinations of tip and sample materials. The validity of the universality discovered for the same metal interfaces is examined for the case of different metal interactions.

Bozzolo, Guillermo↗

NASA NTRS1976

COREST: A FORTRAN computer program to analyze paralinear oxidation behavior and its application to chromic oxide forming alloys

A FORTRAN computer program (COREST) was developed to analyze the high-temperature paralinear oxidation behavior of metals. It is based on a mass-balance approach and uses typical gravimetric input data. COREST was applied to predominantly Cr2O3-forming alloys tested isothermally for long times. These alloys behaved paralinearly above 1100 C as a result of simultaneous scale formation and scale vaporization. Output includes the pertinent formation and vaporization constants and kinetic values of interest. COREST also estimates specific sample weight and specific scale weight as a function of time. Most importantly, from a corrosion standpoint, it estimates specific metal loss.

Barrett, C. E.↗

NASA NTRS1992

Fabrication of silicon-based shape memory alloy micro-actuators

Thin film shape memory alloy has been integrated with silicon in a new actuation mechanism for microelectromechanical systems. This paper compares nickel-titanium film with other actuators, describes recent results of chemical milling processes developed to fabricate shape memory alloy microactuators in silicon, and describes simple actuation mechanisms which have been fabricated and tested.

Johnson, A. David↗

NASA NTRS2002

Oxidation Behavior of Copper Alloy Candidates for Rocket Engine Applications (Technical Poster)

A rocket engine's combustion chamber is lined with material that is highly conductive to heat in order to dissipate the huge thermal load (evident in a white-hot exhaust plume). Because of its thermal conductivity copper is the best choice of liner material. However, the mechanical properties of pure copper are inadequate to withstand the high stresses, hence, copper alloys are needed in this application. But copper and its alloys are prone to oxidation and related damage, especially "blanching" (an oxidation-reduction mode of degradation). The space shuttle main engine combustion chamber is lined with a Cu-Ag-Zr alloy, "NARloy-Z", which exhibits blanching. A superior liner is being sought for the next generation of RLVs (Reusable Launch Vehicles) It should have improved mechanical properties and higher resistance to oxidation and blanching, but without substantial penalty in thermal conductivity. GRCop84, a Cu-8Cr-4Nb alloy (Cr2Nb in Cu matrix), developed by NASA Glenn Research Center (GRC) and Case Western Reserve University, is a prime contender for RLV liner material. In this study, the oxidation resistance of GRCop-84 and other related/candidate copper alloys are investigated and compared

Ogbuji, Linus U. J.↗

NASA NTRS1981

Heat storage in alloy transformations

The feasibility of using metal alloys as thermal energy storage media was determined. The following major elements were studied: (1) identification of congruently transforming alloys and thermochemical property measurements; (2) development of a precise and convenient method for measuring volume change during phase transformation and thermal expansion coefficients; (3) development of a numerical modeling routine for calculating heat flow in cylindrical heat exchangers containing phase change materials; and (4) identification of materials that could be used to contain the metal alloys. Several eutectic alloys and ternary intermetallic phases were determined. A method employing X-ray absorption techniques was developed to determine the coefficients of thermal expansion of both the solid and liquid phases and the volume change during phase transformation from data obtained during one continuous experimental test. The method and apparatus are discussed and the experimental results are presented. The development of the numerical modeling method is presented and results are discussed for both salt and metal alloy phase change media.

Birchenall, C. E.↗

NASA NTRS1986

New Alloy for Glass-to-Metal Seals

Coefficient of thermal expansion approximates that of glass more closely. Alloy composed of about 60 percent iron, 40 percent nickel, and traces of six other elements. Developed as replacement for Kovar Fe/Ni/Co alloy in ferrule-and-tube assembly, new alloy has same strength, solderability, and compatibility with fuel as does Kovar. Used in glass-to-metal seals without excessive residual stresses. Potential for other applications in which low thermal expansion important; mechanical measuring devices and precise sliding parts that must function over wide temperature ranges.

Schmuck, A. J.↗