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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 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Failure Mechanisms During Isothermal Fatigue of SiC/Ti-24Al-11Nb Composites

Failure mechanisms during isothermal fatigue of unidirectional SiC/Ti-24Al-11Nb (at.%) composites have been determined by microstructural analysis of samples from tests interrupted prior to the end of life and from tests conducted to failure. Specimens from three regions of life were examined based on the maximum strain from a fatigue life diagram: Region 1 (high strain), Region 2 (mid-strain) and Region 3 (low strain). Crack lengths were also measured from interrupted samples and compared based on temperature (23-815 C), region of life and numbers of cycles. Region 1 was controlled by fiber-dominated failure. A transition zone was observed between Regions 1 and 2 due to competition between failure mechanisms. Failure in Region 2 was generally described as surface-initiated cracking with varying amounts of fiber bridging. However, the specific descriptions of crack propagation through the fibers and matrix varied with strain and temperature over this broad region. Region 3 exhibited endurance behaviour at 23 C with no cracking after lO(exp 6) cycles. However at 425 C, surface-initiated cracking was observed after 10(exp 6) cycles with fractured fibers in the crack wake. If endurance behaviour exists for conditions of isothermal fatigue in air at temperatures of greater than or equal to 425 C, it may only be found at very low strains and at greater than 10(exp 6) cycles.

Brindley, P. K.↗
NASA NTRS2001

Spin Forming of Aluminum Metal Matrix Composites

An exploratory effort between NASA-Marshall Space Flight Center (MSFC) and SpinCraft, Inc., to experimentally spin form cylinders and concentric parts from small and thin sheets of aluminum Metal Matrix Composites (MMC), successfully yielded good microstructure data and forming parameters. MSFC and SpinCraft will collaborate on the recent technical findings and develop strategy to implement this technology for NASA's advanced propulsion and airframe applications such as pressure bulkheads, combustion liner assemblies, propellant tank domes, and nose cone assemblies.

Lee, Jonathan A.↗
NASA NTRSDate not supplied

Development of Directed Energy Deposited NASA HR-1 to Optimize Properties for Liquid Rocket Engine Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This poster will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

NASA HR-1↗
NASA NTRSDate not supplied

Development and Optimization of Additively Manufactured NASA HR-1 for Space Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This presentation will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

Additive Manufacturing↗
NASA NTRS2011

Filamentous Trichomic Prokaryotes in Carbonaceous Meteorites: Indigenous Microfossils, Minerals, or Modern Bio-Contaminants?

Large complex filaments have been detected in freshly fractured interior surfaces of a variety of carbonaceous meteorites. Many exhibit the detailed morphological and morphometric characteristics of known filamentous trichomic prokaryotic microorganisms. In this paper we review prior studies of filamentous microstructures encountered in the meteorites along with the elemental compositions and characteristics of the, fibrous evaporite minerals and filamentous cyanobacteria and homologous trichomic sulfur bacteria. The meteorite images and elemental compositions will compared with data obtained with the same instruments for abiotic microstructures and living and fossil microorganisms in order to evaluate the relative merits of the alternate hypotheses that have been advanced to explain the nature and characteristics of the meteorite filaments. The possibiility that the filaments found in the meteorites may be comprise modern bio-contaminants will be evaluated in light of their observed elemental compositions and data by other researchers on the detection of indigenous complex organic biosignatures, and extraterrestrial amino acids and nucleobases found in the Murchison CM2 and the Orgueil CI1 carbonaceous meteorites.

Hoover, Richard B.↗
DOE OSTI2025

A snapshot of high-entropy alloy processing techniques and their effects on resulting mechanical properties

High-entropy alloys (HEAs) exhibit exceptional strength, corrosion resistance, and thermal stability, making them promising candidates for nuclear, aerospace, and other extreme applications. While most prior work has focused on compositional design, manufacturing techniques themselves can alter microstructure and mechanical properties as dramatically as alloy chemistry. This review compiles and compares the effects of processing routes—including arc melting, induction melting, mechanical alloying with spark plasma sintering, and additive manufacturing—on the structure and properties of HEAs. Quantitative comparisons highlight, for example, that SPS-processed alloys can achieve ∼20–45 % higher yield and tensile strength than arc-melted counterparts, while Bridgman solidification produces nearly single-crystal structures with elongation to failure exceeding 80 %. Additive manufacturing routes such as selective laser melting offer fine microstructures but also introduce anisotropy and porosity, leading to yield strengths spanning 100–600 MPa for the same composition. By synthesizing such results, this review provides actionable insight into how processing routes interact with HEA core effects (high entropy, lattice distortion, sluggish diffusion, and cocktail effect) to determine performance, thereby offering a practical guide for optimizing manufacturing strategies.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In Situ Prediction of Microstructure and Mechanical Properties in Laser-Remelted Al-Si Alloys: Towards Enhanced Additive Manufacturing

Laser surface remelting of aluminum alloys has emerged as a promising technique to enhance mechanical properties through refined microstructures. This process involves rapid cooling rates ranging from 10 3 to 10 8 °C/s, which increase solid solubility within aluminum alloys, shifting their eutectic composition to a larger value of silicon content. Consequently, the resulting microstructure combines a strengthened aluminum matrix with silicon fibers. This study focuses on the laser scanning of Al-Si aluminum alloy to reduce the size of aluminum matrix spacings and transform fibrous silicon particles from micrometer to nanometer dimensions. Analysis revealed that the eutectic structure contained 17.55% silicon by weight, surpassing the equilibrium eutectic composition of 12.6% silicon. Microstructure dimensions within the molten zones, termed ‘melt pools’, were extensively examined using Scanning Electron Microscopy (SEM) at intervals of approximately 20 μm from the surface. A notable increase in hardness, exceeding 50% compared to the base plate, was observed in the melt pool regions. Thus, it is exemplified that laser surface remelting introduces a novel strengthening mechanism in the alloy. Moreover, this study develops an in situ method for predicting melt pool properties and dimensions. A predictive model is proposed, correlating energy density and spectral signals emitted during laser remelting with mechanical properties and melt pool dimensions. This method significantly reduces characterization time from days to seconds, offering a streamlined approach for future studies in additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Additive manufacturing enabled synergetic strengthening of bimodal reinforcing particles for aluminum matrix composites

An additive manufactured TiB 2 /Al-Cu-Mg-Ni composite with a minor amount of Sc was fabricated by laser powder bed fusion (LPBF). The composite shows a yield strength of ~370 MPa, almost doubling the strength of its wrought matrix counterpart, and an elongation of ~7 %. The superior mechanical properties are attributed to a unique micro-nano hierarchical microstructure, consisting of nanoscale and microscale TiB 2 particles dispersed in a matrix of fine aluminum grains (3 µm) together with intragranular intermetallic nanoparticles and nano-cellular networks (cell size 30 nm). The formation of the TiB 2 nanoparticles is the consequence of partial dissolution of the TiB 2 particulates and the enrichment of Sc in the newly formed nanoparticles. Remarkable strengthening effects are achieved by the bimodal TiB 2 particles, intermetallic nanoparticles and intragranular nano-cellular networks. Finally, this study provides new insights into the role of additive manufacturing in tailoring the microstructure of particulate reinforced metal matrix composites (MMCs) with advanced properties.

36 MATERIALS SCIENCE↗
NASA NTRS1983

The feasibility of low-G grey solidification of nodular iron in the F-104 experimental furnace package

The rationale for low-g experiments with cast iron and the need for solidification in the grey form during these experiments are reviewed. The factors which determine whether an iron melt will solidify grey or white are discussed. Cooling rate versus microstructure was studied for a nodular iron candidate material for F-104 low-g solidification. The study determined that low-g grey solidification, using the present F-104 furnace system, of the nodular iron composition studied is not feasible. Specimen microstructure strongly suggested that the F-104 furnace's gas cooling system was causing excessive localized chill resulting in the nucleation of the unwanted iron carbide phase. A change is suggested, in the quench system design, that could possibly overcome this problem.

Curreri, P. A.↗
NASA NTRS1994

Thermal analysis of a functionally graded material subject to a thermal gradient using the boundary element method

The boundary element method is utilized in this study to conduct thermal analysis of functionally graded composites, materials in which the internal microstructure or properties are explicitly tailored in order to obtain an optimal response, on the micromechanical (constituent) scale. A unique feature of the boundary element formulations used here is the use of circular shape functions to convert the two-dimensional integrations of the composite fibers to one dimensional integrations. Using the computer code BEST-CMS, the through the thickness temperature profiles are computed for a representative material with varying numbers of fibers and fiber spacing in the thickness direction. The computed temperature profiles are compared to those obtained using an alternate analytical theory which explicitly couples the heterogeneous microstructure to the global analysis. The boundary element results compared favorably to the analytical calculations, with discrepancies that are explainable based on the boundary element formulation. The results serve both to demonstrate the ability of the boundary element method to analyze these types of materials, and to verify the accuracy of the analytical theory.

Goldberg, Robert K.↗
DOE OSTI2024

Characterizing Copper-Graphene Composites (Abstract)

In this project, Pacific Northwest National Laboratory (PNNL) will measure the electrical and mechanical properties of the metal composite samples provided by MetalKraft Technologies, LLC. PNNL will also use multimodal methods for characterizing the microstructure of MetalKraft Technologies, LLC’s copper graphene composites. PNNL will work with MetalKraft Technologies, LLC as part of the CABLE Manufacturing Prize efforts under a CRADA. The voucher from DOE has a budget of $100,000 over a period of 6 months. PNNL will be the primary place of performance for the property and microstructure characterization efforts.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Effect of microstructure and notch root radius on fracture toughness of an aluminum metal matrix composite

Recent results on the effects of matrix aging condition (matrix temper) and notch root radius on the measured fracture toughness of a SiC particulate reinforced aluminum alloy are reviewed. Stress intensity factors at catastrophic fracture were obtained for both underaged and overaged composites reveal. The linear relation found between apparent fracture toughness and the square root of the notch root radius implies a linear dependence of the crack opening displacement on the notch root radius. The results suggest a strain controlled fracture process, and indicate that there are differences in the fracture micromechanisms of the two aging conditions.

Manoharan, M.↗
NASA NTRS2000

Gravitational Effects on Combustion Synthesis of Advanced Porous Materials

Combustion Synthesis (self-Propagating high-temperature synthesis-(SHS)) of porous Ti-TiB(x), composite materials has been studied with respect to the sensitivity to the SHS reaction parameters of stoichiometry, green density, gasifying agents, ambient pressure, diluents and gravity. The main objective of this research program is to engineer the required porosity and mechanical properties into the composite materials to meet the requirements of a consumer, such as for the application of bone replacement materials. Gravity serves to restrict the gas expansion and the liquid movement during SHS reaction. As a result, gravitational forces affect the microstructure and properties of the SHS products. Reacting these SHS systems in low gravity in the KC-135 aircraft has extended the ability to form porous products. This paper will emphasize the effects of gravity (low g, 1g and 2g) on the SHS reaction process, and the microstructure and properties of the porous composite. Some of biomedical results are also discussed.

Zhang, X.↗
NASA NTRS1990

Intermetallic matrix composites; Proceedings of the MRS Symposium, San Francisco, CA, Apr. 18-20, 1990

The present volume on intermetallic matrix composites discusses the modeling, processing, microstructure/property relationships, and compatibility of intermetallic matrix composites. Attention is given to models for the strength of ductile matrix composites, innovative processing techniques for intermetallic matrix composites, ductile phase toughening of brittle intermetallics, and reactive synthesis of NbAl3 matrix composites. Topics addressed include solidification processing of NbCr2 alloys, Ta and Nb reinforced MoSi2, the microstructure and mechanical behavior of Ni3Al-matrix composites, and ductile-phase toughening of Cr3Si with chromium. Also discussed are dislocation morphologies in TiB2/NiAl, the development of highly impact resistant NiAl matrix composites, the effect of notches on the fatigue life of the SCS-6Ti3Al composite, and the chemical stability of fiber-metal matrix composites.

Anton, D. L.↗
DOE OSTI2021

Thermally-Driven Changes to Porosity in TATB-Based High Explosives

Ultra-small- and small-angle neutron scattering techniques were employed to quantify thermally driven changes to the microstructure of the TATB-based composite high explosive, PBX 9502. Samples of PBX 9502 were studied in-situ at temperatures ranging from 25 to 220 °C and after re-equilibration at ambient temperature. Significant changes to the void size and morphology within the PBX 9502 microstructure were observed upon heating and are consistent with the known increase in the shock sensitivity of thermally-treated PBX 9502. More extensive microstructural changes were found after the thermally treated samples were re-equilibrated at ambient temperature. Utilizing a model of ramified porosity, the size and the volume and surface dimensions of voids in the PBX 9502 microstructure were quantified as a function of temperature. The temperature dependence of the void radius of gyration is well correlated with the known increase in the shock sensitivity of PBX 9502 with increasing temperature, providing a microstructural origin for the increased shock sensitivity of PBX 9502 at elevated temperatures.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2024

3D Printing of Inconel 718 with Enhanced Boron Composition as a Novel Solar Absorber Tube Material in the Concentrated Solar Power (CSP) System

The growing demands for elevated efficiency in the solar energy industry led researchers to focus on the development of functional solar absorber tube material in concentrated solar power (CSP) systems, when molten salts are adopted as the heat transfer fluid. In this study, the typical solar absorber tube material, Inconel 718, was enhanced with boron to achieve a higher solar absorptivity in the visible light spectrum. Combined with an additive manufacturing (AM) method, the boron composition exceeded the traditional manufacturing limit of 60 ppm without microstructural defects. The boron-enhanced Inconel 718 exhibited a high solar absorptivity of nearly 90 % while maintaining a high thermal cycle fatigue resistance after thermal cycling treatment between 550°C and 720°C. The boron composition was increased to the manufacturing failure point, and the effects of different boron compositions on mechanical properties, microstructure, and optical properties were studied. The provided microstructure-property map in this study delivers high potentials of functional AM-printed alloy material in CSP applications.

13 HYDRO ENERGY↗