LEVERAGING ADDITIVE MANUFACTURING TO FABRICATE HIGH TEMPERATURE ALLOYS WITH CO-DESIGNED MECHANICAL PROPERTIES AND ENVIRONMENTAL RESISTANCE
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Pillai, Rishi↗
SEARCH · Engineering Papers
Results for “High Temperature Properties”
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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Electrical, structural and thermomechanical properties of doped-LaCrO3 ceramics for high temperature electronics and sensing applications.
Many important electrical and sensor applications require stable conductors under working temperatures up to 1500oC various redox environments. Common high temperature conductors such as nitrides and carbides are not stable under oxidizing atmospheres, for this reason low redox behavior materials would be more attractive. In this work, further dopant studies of the LaCrO3 system were completed in order to control the electronic and ionic conductivity, as well as the relative chemical and microstructural stability. Neodymium and Niobium dopants were initially studied to control the p-type, and potentially n-type conductive mechanisms, respectively, but other dopants strategies were also investigated. The electrical conductivity and Seebeck coefficient were characterized up to 1500oC under varying oxygen partial pressures. The phase and microstructural evolution of each material was also investigated for these compositions by XRD and SEM. The materials showing the best electrical and thermomechanical performance were included within thick films sensors and were tested.
20 FOSSIL-FUELED POWER PLANTS↗
Thermodynamic and transport properties and chemical reaction rates for high-temperature air
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Hansen, C. F.↗
Effect of high temperature creep and oxidation on residual room temperature properties for several thin sheet superalloys
Superalloys are being considered for the primary heat shields and supports in the thermal protection system of both hypersonic transport and space shuttle vehicles. Since conservative design philosophy dictates designs based on residual material properties at the end of the service life, material characterization after exposure to the environmental conditions imposed by the flight requirements of these two classes of vehicles is needed on the candidate alloys. An investigation was conducted to provide some of the necessary data, with emphasis placed on oxidation, creep, and residual properties of thin-gage sheet material.
Royster, D. M.↗
Effects of high temperature brazing and thermal cycling on mechanical properties of Hastelloy X.
Data are presented on the effects of brazing alloy, brazing operation, thermal cycling, and combinations of these on the yield strength, elongation, ultimate tensile strength, and fatigue life of thin gage Hastelloy X. These data show that brazing with a Ni-Pd-Au alloy at 1461 K resulted in reductions of 35 percent in yield strength and elongation, 6 percent in ultimate tensile strength, and 18 percent in fatigue limit of Hastelloy X, as compared with as-received material. Subsequent exposure to 200 thermal cycles between 533 K and 1144 K after brazing caused further losses of 4 percent in yield strength, 8 percent in ultimate tensile strength, and 6 percent in fatigue limit.
Dicus, D. L.↗
Tectonics and evolution of Venus
Earlier data synthesized with data recently obtained by the Pioneer Venus Orbiter are analyzed with regard to general tectonics, interior, and long-term evolution of Venus. Comprehensive topographic maps, global properties of Venus, and variations in its gravity field are investigated, and bulk properties of Venus, earth, Mars, the sun, and chondritic meteorites relevant to planetary internal structure and evolution are studied. Although Venus was found to differ less than 30% from earth in comparing all important bulk properties, it appears to have evolved differently. It is noted that a slow rotation rate, the absence of a satellite, the virtual absence of a magnetic field, the dearth of water in the atmosphere, the abundance of primordial argon, and the high surface temperature, are properties in which Venus differs most from the earth. Further results showing the positive correlation of gravity and topography at all wavelengths and the apparent absence of any feature like an ocean indicate that Venus is a one-plate planet and its evolution apparently resembles that of Mars more than that of the earth.
Phillips, R. J.↗
Properties of planetary fluids at high pressure and temperature
In order to derive models of the interiors of Uranus, Neptune, Jupiter and Saturn, researchers studied equations of state and electrical conductivities of molecules at high dynamic pressures and temperatures. Results are given for shock temperature measurements of N2 and CH4. Temperature data allowed demonstration of shock induced cooling in the the transition region and the existence of crossing isotherms in P-V space.
Nellis, W. J.↗
Effect of high-temperature annealing on the microstructure and thermoelectric properties of GaP doped SiGe
Annealing of GaP doped SiGe will significantly alter the thermoelectric properties of the material resulting in increased performance as measured by the figure of merit Z and the power factor P. The microstructures and corresponding thermoelectric properties after annealing in the 1100 to 1300 C temperature range have been examined to correlate performance improvement with annealing history. The figure of merit and power factor were both improved by homogenizing the material and limiting the amount of cross-doping. Annealing at 1215 C for 100 hr resulted in the best combination of thermoelectric properties with a resultant figure of merit exceeding 1x10 to the -3 deg C to the -1 and a power factor of 44 microW/cm/deg C sq for the temperature range of interest for space power: 400 to 1000 C.
Draper, Susan L.↗
Properties of planetary fluids at high pressures and temperatures
Observational data obtained by the Voyager space probes to the giant planets Jupiter, Saturn, Uranus, and Neptune have provided valuable information, which is used to refine the picture of the nature of the interiors of these planets. Major results from the Voyager missions include observations of substantial magnetic fields and improved models of internal density distributions. The goal is to obtain equations of state and electrical conductivity data for planetary gases (H2 and He) and the ices (H2O, CH4, and NH3, and their mixtures), which are considered to be the major constituents of the giant planets. These data are needed to test theoretical data bases used to construct models of the chemical composition of planetary interiors, models which are consistent with observables such as mass, diameter, gravitational moments, rotation rate, and magnetic field. The 100 GPa (1 Mbar) pressures and several 1000 K temperatures in the giant planets can be achieved in the lab by the shock compression of liquid specimens. Results are briefly examined.
Nellis, W. J.↗
Impact Strength and Flexural Properties of Laminated Plastics at High and Low Temperatures
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Lamb, J J↗
Thermomechanical Properties of Bulk Yttrium Hydride for High-Temperature Moderator Application
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Hu, Xunxiang↗
Progress on Producing an ODS Ferritic Alloy by High Deformation Processing of Reactive Powders
Oxide dispersion-strengthened (ODS) ferritic alloys, such as 14YWT, are considered as benchmarks for fuel cladding and core structural materials in advanced nuclear energy reactor systems that require high temperature strength and creep properties as well as resistance to radiation damage. Unfortunately, the popular processing method of mechanical alloying (MA) is time-consuming, incurs high manufacturing costs, and typically produces anisotropy in the microstructure and mechanical properties of ODS ferritic alloys. These considerations hinder their acceptance in many high-performance, high-temperature materials for advanced nuclear energy reactors. This work package is pursuing an alternative solid-state processing to MA involving high deformation at high temperatures for producing an ODS ferritic alloy for fuel cladding. This report summarizes the concept for this processing method and the progress toward selecting the reactive and ferritic alloy powders, preparing 316L stainless steel cans for filling with blended powder followed by degassing, and choosing the heat treatments and forging parameters for performing the first two forging experiments. The preliminary results of optical microscopy performed on polished samples that were cut in three orthogonal directions revealed remnant porosity in both samples. The analysis of the porosity using ImageJ revealed a lesser amount of ~2.49% in the HiLoMe-1 sample that was processed with the three heat treatments and forging parameters compared to ~5.70% for the Hi-1 sample that was processed with only the first sintering heat treatment and forging parameter. These initial results will provide insights that can be leveraged to improve the densification of the powders in future forging experiments that will be continued into FY24 for determining the optimum heat treatments and forging parameters coupled with detailed microstructure characterization studies for producing the ODS ferritic alloy.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Non-contact Creep Resistance Measurement for Ultra-high temperature Materials
Continuing pressures for higher performance and efficiency in propulsion are driving ever more demanding needs for high-temperature materials. Some immediate applications in spaceflight include combustion chambers for advanced chemical rockets and turbomachinery for jet engines and power conversion in nuclear-electric propulsion. In the case of rockets, the combination of high stresses and high temperatures make the characterization of creep properties very important. Creep is even more important in the turbomachinery, where a long service life is an additional constraint. Some very high-temperature materials are being developed, including platinum group metals, carbides, borides, and silicides. But the measurement of creep properties at very high temperatures is itself problematic, because the testing instrument must operate at such high temperatures. Conventional techniques are limited to about 1700 C. A new, containerless technique for measuring creep deformation has been developed. This technique is based on electrostatic levitation (ESL) of a spherical sample, which is heated to the measurement temperature and rotated at a rate such that the centrifugal acceleration causes creep deformation. Creep of samples has been demonstrated at up to 2300 C in the ESL facility at NASA MSFC, while ESL itself has been applied at over 3000 C, and has no theoretical maximum temperature. The preliminary results and future directions of this NASA-funded research collaboration will be presented.
Hyers, Robert W.↗
Microstructural evolution, defect mitigation, and precipitation behavior in AA6061 via laser powder bed fusion with high-temperature substrate heating
Defects, particularly solidification cracking, remain persistent challenges in the laser powder bed fusion (LPBF) processing of AA6061 aluminum alloy. This study systematically investigates defect mitigation, microstructural evolution, and mechanical properties associated with high-temperature substrate preheating at 500 °C. Comprehensive microstructural analyses, including characterization of defects, grain structures, and precipitation behavior, were performed on samples in both as-built and T6 heat-treated states. Elevated preheating substantially reduced solidification cracking across a wide processing window, while demonstrating decreased crack sensitivity to laser parameters. Columnar cracks along the build direction were observed despite substrate preheating. Lack-of-fusion and keyhole porosity were effectively eliminated, though gas-induced microporosity persisted at higher powers. In-depth characterization of two distinct laser power and speed conditions confirmed the formation of micron-sized, non-coherent Mg 2 Si precipitates under heated substrate conditions, alongside α-AlFeCrMnSi intermetallic phases indicative of in-situ thermal effects during fabrication. Subsequent T6 heat treatment revealed the formation of fine, coherent needle-shaped β″ strengthening precipitates. Despite substantial differences in processing parameters, comparable mechanical properties were measured in the as-built samples (∼52 MPa yield strength, ∼130 MPa tensile strength), primarily due to reduced strain hardening effects and consistent precipitation characteristics. Meanwhile, the T6 heat treatment led to significant improvement in properties, enhancing yield strength by over 400%, aligning closely with the performance of conventional wrought AA6061-T6. These findings underscore that high-temperature substrate preheating offers an effective means to suppress cracks, control precipitation, and enhance mechanical performance in LPBF-processed AA6061.
36 MATERIALS SCIENCE↗
Thermal-Mechanical Analysis of an Additive Manufacturing Ceramic Heat Exchanger for High-Temperature Recuperator in a sCO2 Power System
Supercritical CO2 (sCO2) Brayton power cycle can be configured in a closed-loop power system and has a potentially high cycle efficiency. Compactness and high efficiency of a sCO2 power block make the sCO2 Brayton cycle a versatile power cycle in broad applications. While many heat sources are of sufficient intensity to produce high temperature working fluids to achieve high cycle efficiency, the thermal-mechanical stability of traditional materials (e.g., steels and nickel-based superalloys) used in construction of heat exchangers and turbine components limits the operating conditions and thus thermodynamic efficiency of the system. This effort seeks to establish the viability of ceramic heat exchanger technologies for the most extreme operating conditions envisioned for power generation and other high temperature processes. Heat exchangers constructed from ultra-high temperature ceramics, a class of extreme environment materials featuring melting points (Tmp.) above 3000 degrees C, is particularly appealing for sCO2 Brayton cycles given their ultra-low creep rates and very high retained strength at low homologous temperatures (i.e., T < 0.5 Tmp., or at least 1500 degrees C). To translate these materials properties to ultra-high temperature heat exchangers, innovations are required in ceramic manufacturing techniques to realize the complex architectures featured in compact heat exchangers with high power density. With appropriate processing, ZrB2-SiC based compositions can be sintered to near full density and shaped into complex topologies via ceramic additive manufacturing methods. This paper analyzes heat exchanger designs and explores thermal-mechanical implications of the operating environment. Thermal flow, heat transfer, and conjugate mechanical analyses provide insights into benefits and risks associated with the design approach.
additive manufacturing↗
Theoretical Prediction of Thermal Expansion Anisotropy for Y 2 Si 2 O 7 Environmental Barrier Coatings Using a Deep Neural Network Potential and Comparison to Experiment
Environmental barrier coatings (EBCs) are an enabling technology for silicon carbide (SiC)-based ceramic matrix composites (CMCs) in extreme environments such as gas turbine engines. However, development of new coating systems is hindered by the large design space and difficulty in predicting properties for these materials. Density Functional Theory (DFT) has successfully been used to model and predict some thermodynamic and thermo-mechanical properties of high-temperature ceramics for EBCs, although these calculations are challenging due to their high computational costs. In this work, we use machine learning to train a deep neural network potential (DNP) for Y 2 Si 2 O 7 , which is then applied to calculate thermodynamic and thermo-mechanical properties at near-DFT accuracy much faster and using less computational resources than DFT. We use this DNP to predict phonon-based thermodynamic properties of Y 2 Si 2 O 7 with good agreement to DFT and experiments. We also utilize the DNP to calculate the anisotropic, lattice direction-dependent coefficients of thermal expansion (CTEs) for Y 2 Si 2 O 7 . Molecular dynamics trajectories using the DNP correctly demonstrate accurate prediction of the anisotropy of the CTE in good agreement with diffraction experiments. In the future, this DNP could be applied to accelerate additional property calculations for Y 2 Si 2 O 7 compared to DFT or experiments.
rare earth silicates↗
Theoretical Prediction of Thermal Expansion Anisotropy for Y 2 Si 2 O 7 Environmental Barrier Coatings Using a Deep Neural Network Potential and Comparison to Experiment
Environmental barrier coatings (EBCs) are an enabling technology for silicon carbide (SiC)-based ceramic matrix composites (CMCs) in extreme environments such as gas turbine engines. However, the development of new coating systems is hindered by the large design space and difficulty in predicting the properties for these materials. Density Functional Theory (DFT) has successfully been used to model and predict some thermodynamic and thermo-mechanical properties of high-temperature ceramics for EBCs, although these calculations are challenging due to their high computational costs. In this work, we use machine learning to train a deep neural network potential (DNP) for Y 2 Si 2 O 7 , which is then applied to calculate the thermodynamic and thermo-mechanical properties at near-DFT accuracy much faster and using less computational resources than DFT. We use this DNP to predict the phonon-based thermodynamic properties of Y 2 Si 2 O 7 with good agreement to DFT and experiments. We also utilize the DNP to calculate the anisotropic, lattice direction-dependent coefficients of thermal expansion (CTEs) for Y 2 Si 2 O 7 . Molecular dynamics trajectories using the DNP correctly demonstrate the accurate prediction of the anisotropy of the CTE in good agreement with the diffraction experiments. In the future, this DNP could be applied to accelerate additional property calculations for Y 2 Si 2 O 7 compared to DFT or experiments.
36 MATERIALS SCIENCE↗
Properties of materials in high pressure hydrogen at room and elevated temperatures
Experimental efforts in this program for this period. Mechanical property tests of wrought and cast nickel-base alloys and one wrought cobalt-base alloy were conducted in 34.5 MN/sq m (5000-psig) helium and hydrogen or hydrogen mixtures. Comparison of test results was made to determine degradation of properties due to the hydrogen environments. All testing was conducted on solid specimens exposed to external gaseous pressure. Specific mechanical properties determined and the testing methods used are summarized.
Harris, J. A., Jr.↗