Development of a Graded Surface Modification Of Alloys For Containment Of Chloride Molten Salts
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14 SOLAR ENERGY↗
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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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Development of high performance high-entropy alloys and evaluation of radiation response under stress
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Kim, Hyosim↗
Design and development of equi-atomic high entropy alloys for use in irradiation environments
Presentation for conference
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Microsample Characterization of Coatings for Grcop-84 for High Heat Flux Applications
A multidisciplinary Johns Hopkins University-NASA Glenn team is undertaking a collaborative research program to elucidate and model the thermal stability and mechanical integrity of candidate coatings for GRCop-84. GRCop-84 is a high conductivity, high strength copper alloy that was recently developed at NASA Glenn for use in high temperature, high heat flux applications. With potential applications in rocket motor combustion chamber liners, nozzle ramps and other actively cooled structures, this new material offers great potential for decreasing weight and increasing reliability of third generation reusable launch vehicles. Current emphasis has turned toward the development of environmentally resistant and thermal barrier coatings for this alloy. Metallic coatings such as NiCrAlY and Cu-8-30%Cr have shown promise in: prohibiting blanching, reducing dog-house failures, increasing operating temperatures and decreasing cooling requirements. The focus of this research program is to develop a fundamental understanding of the substrate-coating interactions that occur during thermal cycling (inter-diffusion, viscoplasticity, morphological evolution, crack formation, etc.) and to derive a science-based protocol for future coating selection, optimization and reliability assurance. The microsample tensile testing approach adopted for this study allows us to characterize small-scale and highly scale-specific coatings and properties in a way not possible by conventional means. In addition to providing much needed design data, the integration of microsample testing with detailed microstructural observations provides a mechanistic foundation for coating optimization and life prediction modeling.
Hemker, Kevin↗
Analytical study of space processing of immiscible materials for superconductors and electrical contacts
The results of a study conducted to determine the role space processing or materials research in space plays in the superconductor and electrical contact industries are presented. Visits were made to manufacturers, users, and research organizations connected with these products to provide information about the potential benefits of the space environment and to exchange views on the utilization of space facilities for manufacture, process development, or research. In addition, space experiments were suggested which could result in improved terrestrial processes or products. Notable examples of these are, in the case of superconductors, the development of Nb-bronze alloys (Tsuei alloys) and, in the electrical contact field, the production of Ag-Ni or Ag-metal oxide alloys with controlled microstructure for research and development activities as well as for product development. A preliminary experimental effort to produce and evaluate rapidly cooled Pb-Zn and Cu-Nb-Sn alloys in order to understand the relationship between microstructure and superconducting properties and to simulate the fine structure potentially achievable by space processing was also described.
Gelles, S. H.↗
Nondissipative Martensitic Phase Transformation after Multimillion Superelastic Cycles
Superelastic alloys used for stents, biomedical implants, and solid-state cooling devices rely on their reversible stress-induced martensitic transformations. These applications require the alloy to sustain high deformability over millions of cycles without failure. Here, we report an alloy capable of enduring 10 × 10 7 tensile stress-induced phase transformations while still exhibiting over 2% recoverable elastic strains. After millions of cycles, the alloy is highly reversible with zero stress hysteresis. We show that the major martensite variant is reversible even after multimillions of cycles under tensile loadings with a highly coherent $(1\bar{1}0)_A$ interface. Finally, this discovery provides new insights into martensitic transformation, and may guide the development of superelastic alloys for multimillion cycling applications.
36 MATERIALS SCIENCE↗
Developing techniques for crystal growth synthesis and characterization of rare earth-silicon-germanium magnetoresponsive alloys
In this study, a crystal growth technique was developed for the family of intermetallic, magnetoresponsive RE 5 (Si 1-x Ge x ) 4 alloys in order to access the intrinsic and anisotropic properties. Initial bulk properties measured on polycrystalline samples alluded to the properties being obscured or averaged and high-quality, well-characterized, single crystals would clarify this. Successful crystal growth led to development of oriented sample preparation techniques specific for the crystal structures (monoclinic and orthorhombic) and mechanical properties (hard and brittle) of these alloys, and customized for the various measurement techniques undertaken. Here we describe our journey, sometimes circuitous, from crystal growth to sample preparation and cite the scientific discoveries that came about as a result.
36 MATERIALS SCIENCE↗
Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process
Next-generation, regeneratively cooled rocket engines require materials that can meet high temperatures while resisting the corrosive oxidation-reduction reaction of combustion known as blanching, the main cause of engine failure. A project was initiated at NASA-Marshal Space Flight Center (MSFC) to combine three existing technologies to build and demonstrate an advanced liquid rocket engine combustion chamber that would provide a 100 mission life. Technology developed in microgravity research to build cartridges for space furnaces was utilized to vacuum plasma spray (VPS) a functional gradient coating on the hot wall of the combustion liner as one continuous operation, eliminating any bondline between the coating and the liner. The coating was NiCrAlY, developed previously as durable protective coatings on space shuttle high pressure fuel turbopump (HPFTP) turbine blades. A thermal model showed that 0.03 in. NiCrAlY applied to the hot wall of the combustion liner would reduce the hot wall temperature 200 F, a 20% reduction, for longer life. Cu-8Cr-4Nb alloy, which was developed by NASA-Glenn Research Center (GRC), and which possesses excellent high temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability, was utilized as the liner material in place of NARloy-Z. The Cu-8Cr-4Nb material exhibits better mechanical properties at 650 C (1200 F) than NARloy-Z does at 538 C (1000 F). VPS formed Cu-8Cr-4Nb combustion chamber liners with a protective NiCrAlY functional gradient coating have been hot fire tested, successfully demonstrating a durable coating for the first time. Hot fire tests along with tensile and low cycle fatigue properties of the VPS formed combustion chamber liners and witness panel specimens are discussed.
Holmes, Richard↗
Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures
NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.
Additive Manufacturing↗
Dentritic morphology and microsegregation in directionally solidified superalloy, PWA-1480, single crystal: Effect of gravity; center director's discretionary fund report
Primary dendrite spacings, secondary dendrite spacings, and microsegregation have been examined in PWA-1480 single crystal specimens which were directionally solidified during parabolic maneuvers on the KC-135 aircraft. Experimentally observed growth rate and thermal gradient dependence of primary dendrite spacings are in good agreement with predictions from dendrite growth models for binary alloys. Secondary dendrite coarsening kinetics show a reasonable fit with the predictions from an analytical model proposed by Kirkwood for a binary alloy. The partition coefficients of tantalum, titanium, and aluminum are observed to be less than unity, while that for tungsten and cobalt are greater than unity. This is qualitatively similar to the nickel base binaries. Microsegregation profiles experimentally observed for PWA-1480 superalloy show a good fit with Bower, Brody, and Flemings model developed for binary alloys. Transitions in gravity levels do not appear to affect primary dendrite spacings. A trend of decreased secondary arm spacings with transition from high gravity to the low gravity period was observed at a growth speed of 0.023 cm s(exp -1). However, definite conclusions can only be drawn by experiments at lower growth speeds which make it possible to examine the side-branch coarsening kinetics over a longer duration. Such experiments, not possible due to the insufficient low-gravity time of the KC-135, may be carried out in the low-gravity environment of space.
Tewari, S. N.↗
High Entropy Alloy Catalysis for Ammonia Decomposition
In this set of experiments, the focus is on developing a high entropy alloy catalyst to decompose ammonia into it two basic atomic elements; N2 and H2. 2𝑁𝐻3 ⇌ 𝑁2 + 3𝐻2 This must be done for the purpose of industrial release of ammonia into the atmosphere in a safer, healthier way. The goal behind this project was to create a catalyst with equal efficiency to ruthenium-based catalysts, which are the current industry standard. Using ruthenium at scale is cost prohibitive and is a hinderance to higher adoption of a hydrogen fuel economy.
Qutob, Laila A. [Savannah River National Laborator↗
Development of high-cycle fatigue design curves for a cast aluminum alloy
Life prediction curves for rocket engine pump parts were developed from the results of high-cycle fatigue tests run on cast-aluminum specimens. Notched and smooth specimens were cyclically tested at different mean stress levels at -320 F (78 K). The notch size and mean stress enveloped the design operating conditions. Local stress computed in the groove of the notched specimen was used to represent its fatigue strength. The von Mises criterion was used to determine effective cyclic stresses. The Goodman rule was applied to determine equivalent reversed alternating stresses. The procedure permitted the notched and smooth data sets to each be described by a single curve. High-cycle fatigue life curves were provided for the stress state, mean stress, and stress concentration spanned by the data.
Cooper, R. A.↗
BOILER Experiment Material Characterization and HFIR Irradiation Status
Pre-oxidized alumina-forming austenitic (AFA) steels have been previously identified as candidate alloys for structural components in lead-cooled fast reactors (LFRs). They offer compatibility with liquid Pb, high-temperature strength, formability, and cost advantages. However, variations in Ni content can affect the formation and stability of the Al 2 O 3 layer, influencing compatibility with liquid Pb. The effect of fast neutron irradiation on Al 2 O 3 stability in liquid Pb also requires evaluation. Therefore, understanding how Ni concentrations impacts pre-oxidized AFAs under combined extremes of irradiation and liquid metal corrosion is essential before safe deployment. The Behavior Of In-situ Lead Environments & Radiation (BOILER) experiment was developed under the Nuclear Science User Facilities (NSUF) program to integrate alloy development, irradiation experiment design, and irradiated materials characterization. In this effort, two pre-oxidized AFA steels with 20 wt% and 25 wt% Ni, hereinafter referred to as GA05-20Ni and GA05-25Ni, were produced. An irradiation experiment was then planned for the High Flux Isotope Reactor (HFIR), designed for passive heating of irradiation rabbit capsules from gamma heating in the HFIR flux trap (1 × 10 15 n/cm 2 ·s, >0.1 MeV). This heating melts Pb and exposes the pre-oxidized AFA steel specimens to nominal temperatures of 400 and 650°C. Detailed neutronics and thermal analyses were performed, though based on nominal design rather than as-built, as-irradiated conditions. This report documents further characterization of the pre-oxidized AFAs in the unirradiated condition. It also includes as-built thermal analysis using measured component dimensions, updated fill gas concentrations, and actual HFIR irradiation positions. Finally, the report summarizes capsule fabrication, current irradiation status, projected completion, estimated damage accumulation, and initial plans for post-irradiation examination plans.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Assessment of Shape Memory Alloys - From Atoms To Actuators - Via In Situ Neutron Diffraction
As shape memory alloys (SMAs) become an established actuator technology, it is important to identify the fundamental mechanisms responsible for their performance by understanding microstructure performance relationships from processing to final form. Yet, microstructural examination of SMAs at stress and temperature is often a challenge since structural changes occur with stress and temperature and microstructures cannot be preserved through quenching or after stress removal, as would be the case for conventional materials. One solution to this dilemma is in situ neutron diffraction, which has been applied to the investigation of SMAs and has offered a unique approach to reveal the fundamental micromechanics and microstructural aspects of bulk SMAs in a non-destructive setting. Through this technique, it is possible to directly correlate the micromechanical responses (e.g., internal residual stresses, lattice strains), microstructural evolutions (e.g., texture, defects) and phase transformation properties (e.g., phase fractions, kinetics) to the macroscopic actuator behavior. In this work, in situ neutron diffraction was systematically employed to evaluate the deformation and transformation behavior of SMAs under typical actuator conditions. Austenite and martensite phases, yield behavior, variant selection and transformation temperatures were characterized for a polycrystalline NiTi (49.9 at. Ni). As the alloy transforms under thermomechanical loading, the measured textures and lattice plane-level variations were directly related to the cyclic actuation-strain characteristics and the dimensional instability (strain ratcheting) commonly observed in this alloy. The effect of training on the shape memory characteristics of the alloy and the development of two-way shape memory effect (TWSME) were also assessed. The final conversion from a material to a useful actuator, typically termed shape setting, was also investigated in situ during constrained heatingcooling and subsequent shape recovery experiments. Neutron diffraction techniques are also being applied to the investigation of novel high temperature SMAs with the objective of designing alloys with better stability, higher transition temperatures and ultimately superior durability.
Shape Memory Alloys↗
Designing alloys with process-mapping AI pre-trained on empirical knowledge
<span style="font-family: Calibri, sans-serif; font-size: 12pt;">Accelerated materials design should match the recent trends in the product development cycles. Materials data analytics can be used to significantly shorten development time of specialized alloys needed for next generation energy applications. However, it faces a challenge of scarce data available for training ML models. Incorporation of the domain knowledge into deep-learning graph structure via fuzzy pre-training and causal process imitation presents a viable approach to developing accurate data-driven models and reliable alloy design tools, with limited datasets. Artificial Intelligence (AI) was used in this study to incorporate such knowledge in the domain-specific computational tool, pyroMind. The tool provides not only novel design ideas but also their interpretation via physics and engineering concepts.</span>
Romanov, Vyacheslav↗
GRCop-42 Development and Hot-fire Testing Using Additive Manufacturing Powder Bed Fusion for Channel-Cooled Combustion Chambers
GRCop-42 is a high conductivity, high-strength dispersion strengthened copper-alloy for use in high heat flux applications such as liquid rocket engine combustion devices. This alloy is part of the family of NASA-developed GRCop, copper-chrome-niobium alloys. GRCop alloys were developed for harsh environments specific to regeneratively-cooled combustion chambers and nozzles with good oxidation resistance. Significant development was completed on the GRCop-84 and GRCop-42 alloys in the extruded wrought form demonstrating feasibility for combustion chambers. NASA has recently developed a process for additive manufacturing, specifically Powder Bed Fusion (PBF) or Selective Laser Melting (SLM), of GRCop-42 to establish parameters, characterize the material, and complete testing of components with complex internal features. This evolution of the GRCop-42 was based on the successful predecessor development work using GRCop-84 with the motivation of establishing a new copper-alloy option for use in NASA, government, and industry programs with SLM. A few advantages have been shown with the GRCop-42 that include higher conductivity and faster build speeds over the GRCop-84, and a simplified powder supply chain. Initial property development has shown that it is possible to produce high density builds with strengths equivalent to wrought GRCop-42 and a conductivity greater than GRCop-84. The GRCop-42 has completed process development and initial properties have been established. Several demonstrator combustion chambers have also been fabricated with the SLM GRCop-42 that include integral channels and closeouts. Additional test units have been fabricated and are completing substantial hot-fire testing to demonstrate performance of the material, process, and design.
Gradl, Paul R.↗
A Discussion of Strength Reduction Factor Development for Thermal Aging Effect on Nuclear Structural Alloys
In consideration of structural alloy property deterioration during long-term exposure to elevated temperatures, the yield and ultimate tensile strength reduction factors are provided in the Boiler and Pressure Vessel Code Section III for nuclear reactor component design and operation analysis. Because the Gen IV reactor requirement of 40 ~ 60 years of service life makes it difficult to acquire such long exposure test data for developing the reduction factors, they must be derived from test data with relatively short exposure by predictive methods considered to be reasonably reliable. A novel approach with a physically-based model has recently been proposed for application to development of reduction factors for 9Cr-1Mo-V. In the model, contributors to the tensile strength are first identified and related to definite microstructural features of the alloy, then some physically-based methods are employed to simulate the microstructural evolution, and finally the model is assembled with test-data-calibrated parameters to generate the yield and ultimate tensile strength reduction factors covering elevated temperature exposure for up to 57 years. The approach is undoubtedly a trailblazing development that will, if proven reliable, lead to a paradigm shift in predicting thermal aging behavior of many other alloys. Its debut application to Section III, however, concerns nuclear safety and naturally warrants objective, impartial, and thorough technical scrutiny. In the present paper, the novel and conventional approaches are discussed. Necessary improvements to the novel approach are recommended for its application to nuclear structural component design and analysis, and for its potential expanded use to other alloys.
Ren, Weiju↗
Reliability Modeling of Brittle Anisotropic Materials
A significant effort is being made to develop testing and design methodologies that will account for the lack of ductility and the strength anisotropy exhibited by brittle single crystals such as NiAl. The present approach is to modify existing test methods and brittle design methodologies, such as those applied to ceramics and glasses, and to experimentally verify the results. This paper focuses on the basic materials properties and strength behavior of a NiAl single crystal alloy and the development of a reliability model for the design of components subjected to multiaxial stresses.
Conceivably↗