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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Effect of die design on microstructure and mechanical joint strength in friction self-piercing riveted AA7055-T76 and AA7055-T76

In the present study, a unique friction self-piercing riveting (F-SPR) was applied to join high-strength, low-ductility aluminum alloy (AA) 7055-T76 and AA7055-T76 to mitigate a cracking issue. Also, the effect of die design on both joint formation and the mechanical joint performance were investigated. A crack-free joint was achieved when joining AA7055-T76 and AA7055-T76 by F-SPR. As the bottom diameter of the die increased, the mechanical interlocking distance initially increased then became almost saturated. At the same time, the solid-state bonding gradually disappeared, and the lap-shear fracture changed from bottom aluminum fracture to rivet pull-out with partial bottom aluminum fracture. The average maximum lap-shear joint strength of 11.57 kN and cross tension of 5.65 kN were achieved from the D2 die design owing to the combined contributions from high mechanical interlocking distance and good solid-state bonding at the joint interface. Ultrafine grain refinement was observed at the region next to the rivet shank outer surface and along the materials flow line between the top and bottom aluminum sheet in the rivet cavity. Further, because of the same joint-process parameters, the hardness profile at the joints made by different dies did not show obvious differences. As the distance from the base metal to the rivet outer surface decreased, frictional heat caused the hardness to initially decrease from 190 to 150 HV in the heat-affected zone. Hardness increased up to 175 HV in the thermomechanical affected zone (TMAZ-I) owing to large plastic deformation.

36 MATERIALS SCIENCE↗
NASA NTRS1967

Study to minimize hydrogen embrittlement of ultrahigh-strength steels

Hydrogen-stress cracking in high-strength steels is influenced by hydrogen content of the material and its hydrogen absorption tendency. Non-embrittling cleaning, pickling, and electroplating processes are being studied. Protection from this hydrogen embrittlement is important to the aerospace and aircraft industries.

Elsea, S. T.↗
NASA NTRS2019

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.↗
DOE OSTI2022

Exploring the deformation behavior of nanotwinned Al–Zr alloy via in situ compression

Nanotwinned metals have demonstrated the capacity for concomitant high strength and ductility. However, metals with high stacking fault energies, such as aluminum (Al), have a low propensity for twin formation. Here, we show the fabrication of supersaturated solid-solution Al–Zr alloys with a high density of growth twins. Incoherent twin boundaries (ITBs) are strong barriers to dislocation motion, while mobile partial dislocations promote plasticity. These deformable nanotwinned Al–Zr alloys reach a flow stress of ∼1 GPa, as demonstrated using in situ micropillar compression tests. Density functional theory calculations uncover the role Zr solute plays in the formation and deformation of the nanotwinned microstructure. This study features a strategy for incorporating ITBs and 9R phase into Al alloys for simultaneous benefits to strength and deformability.

Richter, N. A. (ORCID:0000000332732276)↗
NASA NTRS1983

Low-Weight Inserts for Aluminum Honeycomb Panels

Fiber/epoxy composites used in place of solid aluminum. New proposal suggests to make inserts out of such lightweight, high strength materials as fiber/epoxy composites or high density aluminum honeycomb. Composite insert is same size and shape as aluminum insert it replaces.

Bumgarner, G. S.↗
NASA NTRS1986

Producing Silicon Carbide/Silicon Nitride Fibers

Manufacturing process makes CxSiyNz fibers. Precursor fibers spun from extruding machine charged with polycarbosilazane resin. When pyrolyzed, resin converted to cross-linked mixture of silicon carbide and silicon nitride, still in fiber form. CxSiyNz fibers promising substitutes for carbon fibers in high-strength, low-weight composites where high electrical conductivity unwanted.

Source record↗
NASA NTRS2004

E-beam-Cure Fabrication of Polymer Fiber/Matrix Composites for Multifunctional Radiation Shielding

Aliphatic polymers were identified as optimum radiation polymeric shielding materials for building multifunctional structural elements. Conceptual damage-tolerant configurations of polyolefins have been proposed but many issues on the manufacture remain. In the present paper, we will investigate fabrication technologies with e-beam curing for inclusion of high-strength aliphatic polymer fibers into a highly cross-linked polyolefin matrix. A second stage of development is the fabrication methods for applying face sheets to aliphatic polymer closed-cell foams.

Wilson, John W.↗
NASA NTRS2004

Photo-Curing: UV Radiation curing of polymers

The Polymers Branch of the Materials Division is dedicated to the development of high-performance for a variety of applications. Areas of significant interest include high- temperature polymers, low density, and high strength insulating materials, conductive polymers, and high density polymer electrolytes. This summer our group is working diligently on a photo-curing project. There is interest in the medical community feel the need for a new and improved balloon that will be used for angioplasty (a form of heart surgery). This product should maintain flexibility but add many other properties. Like possibly further processability and resistance to infection. Our group intends on coming up with this product by using photo-enolization (or simply, photo-curing) by Diels-Alder trapping. The main objective was to synthesize a series of new polymers by Diels-Alder cycloaddition of photoenols with more elastomeric properties. Our group was responsible for performing the proper photo-curing techniques of the polymers with diacrylates and bismaleimides, synthesizing novel monomers, and evaluating experimental results. We attempted to use a diacrylate to synthesize the polymer because of previous research done within the Polymers Branch here at NASA. Most acrylates are commercially available, have more elastometric properties than a typical rigid aromatic structure has and they contain ethylene oxides in the middle of their structure that create extensive flexibility. The problem we encountered with the acrylates is that they photo chemically and thermally self polymerize and create diradicals at low temperatures; these constraints caused a lot of unnecessary side reactions. We want to promote solely, diketone polymerization because this type of polymerization has the ability to cause very elastic polymers. We chose to direct our attention towards the usage of maleimides because they are known for eliminating these unnecessary side reactions.

Inman, Christina A.↗
NASA NTRS2006

2006 Status of the Momentum eXchange Electrodynamic Re-Boost (MXER) Tether Development

The MXER Tether technology development is a high-payoff/high-risk investment area within the NASA In-Space Propulsion Technology (ISPT) Program. The ISPT program is managed by the NASA Headquarters Science Mission Directorate and implemented by the Marshall Space Flight Center in Huntsville, Alabama. The MXER concept was identified and competitively ranked within NASA's comprehensive Integrated In-Space Transportation Plan (IISTP); an agency-wide technology assessment activity. The objective of the MXER tether project within ISPT is to advance the technological maturation level for the MXER system, and its subsystems, as well as other space and terrestrial tether applications. Recent hardware efforts have focused on the manufacturability of space-survivable high-strength tether material and coatings, high-current electrodynamic tether, lightweight catch mechanism, high-accuracy propagator/predictor code, and efficient electron collection/current generation. Significant technical progress has been achieved with modest ISPT funding to the extent that MXER has evolved to a well-characterized system with greater capability as the design has been matured. Synergistic efforts in high-current electrodynamic tethers and efficient electron collection/current generation have been made possible through SBIR and STTR support. The entire development endeavor was orchestrated as a collaborative team effort across multiple individual contracts and has established a solid technology resource base, which permits a wide variety of future space cable/tether applications to be realized.

Bonometti, Joseph A.↗
NASA NTRS2007

Development and Evaluation of TiAl Sheet Structures for Hypersonic Applications

A cooperative program between the National Aeronautics and Space Administration (NASA), the Austrian Space Agency (ASA), Pratt & Whitney, Engineering Evaluation and Design, and Plansee AG was undertaken to determine the feasibility of achieving significant weight reduction of hypersonic propulsion system structures through the utilization of TiAl. A trade study defined the weight reduction potential of TiAl technologies as 25 to 35 percent compared to the baseline Ni-base superalloy for a stiffener structure in an inlet, combustor, and nozzle section of a hypersonic scramjet engine (ref. 1). A scramjet engine inlet cowl flap was designed, along with a representative subelement, using design practices unique to TiAl. A sub-element was fabricated and tested to assess fabricability and structural performance and validate the design system. The TiAl alloy selected was Plansee's third generation alloy Gamma Met PX (Plansee AG ), a high temperature, high strength gamma-TiAl alloy with high Nb content (refs. 2 and 3). Characterization of Gamma Met PX sheet, including tensile, creep, and fatigue testing was performed. Additionally, design-specific coupons were fabricated and tested in order to improve subelement test predictions. Based on the sheet characterization and results of the coupon tests, the subelement failure location and failure load were accurately predicted.

Draper, S. L.↗
NASA NTRS2016

Radio Frequency Plasma Synthesis of Boron Nitride Nanotubes (BNNTs) for Structural Applications: Part I

It is evident that nanotubes, such as carbon, boron nitride and even silicon, offer great potential for many aerospace applications. The opportunity exists to harness the extremely high strength and stiffness exhibited by high-purity, low-defect nanotubes in structural materials. Even though the technology associated with carbon nanotube (CNT) development is mature, the mechanical property benefits have yet to be fully realized. Boron nitride nanotubes (BNNTs) offer similar structural benefits, but exhibit superior chemical and thermal stability. A broader range of potential structural applications results, particularly as reinforcing agents for metal- and ceramic- based composites. However, synthesis of BNNTs is more challenging than CNTs mainly because of the higher processing temperatures required, and mass production techniques have yet to emerge. A promising technique is radio frequency plasma spray (RFPS), which is an inductively coupled, very high temperature process. The lack of electrodes and the self- contained, inert gas environment lend themselves to an ultraclean product. It is the aim of this White Paper to survey the state of the art with regard to nano-material production by analyzing the pros and cons of existing methods. The intention is to combine the best concepts and apply the NASA Langley Research Center (LaRC) RFPS facility to reliably synthesize large quantities of consistent, high-purity BNNTs.

Hales, Stephen J.↗
DOE OSTI2022

Rapid assessment of interfacial stabilization mechanisms of metastable precipitates to accelerate high-temperature Al-alloy development

Precipitate strengthened high-temperature alloys are currently used in safety-critical applications. Understanding precipitate stability and solute segregation mechanisms at high temperatures is key to designing high-strength alloys. Rapid in-situ approaches, therefore, are pivotal in accelerating the alloy design process. Hereby using the test case of a promising high-temperature Al-Cu-Mn-Zr alloy, we demonstrate the value of in-situ atom probe tomography coupled with in-situ transmission electron microscopy to reveal atomic-scale mechanisms that lead to the emergence of non-equilibrium solute segregation. Mn and Zr segregation at strengthening precipitate(θ’)-matrix interface increases the kinetic barrier for phase transformation thus retaining high-temperature strength.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Review of Medium-Mn, Low-Density Steels for Transportation Applications

Low-density steels constitute a broad and complex alloy space (Fe–Mn–Al–C) suitable for a variety of applications. In particular, there has been growing interest in duplex (ferrite + austenite) or multiphase (+ martensite, carbides) low-density steels as a lightweight, advanced high-strength steel (AHSS) for vehicle applications, spurred by extensive decarbonization efforts. Medium-Mn (med-Mn) (3 to 12 wt pct) steels with 3.5 to 10 wt pct Al additions have decreased densities, presenting an interesting opportunity for high-specific strength, intrusion-resistant, and energy-absorbing sheet components with reduced alloying contents compared to high-Mn grades like austenitic Fe–Mn–Al–C or twinning-induced plasticity steels. Compared to leaner med-Mn steels, the physical metallurgy of med-Mn, low-density steels (MMLS) is complex and distinguished by increased δ-ferrite fractions and austenite stacking fault energies, decreased martensite start temperatures, and modified phase transformation windows. Mechanical properties of MMLS are comparable to 3rd generation AHSS, attributable to the unique, multiphase microstructures, and the array of strengthening mechanisms that can be accessed. Despite this, challenges and unknowns remain with respect to their industrial implementation, and new processing routes may need to be developed. Here, this review aims to highlight the composition effects, processing methods, microstructural evolution, deformation behavior, and application properties geared toward manufacturing and performance, altogether assessing the potential of MMLS for transportation applications.

36 MATERIALS SCIENCE↗