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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 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
NASA NTRS1966

Design of thick honeycomb core structures

The demand for weight reduction in flight vehicles suggests the use of lightweight sandwich structures. Several factors must be considered to obtain minimum-weight sandwich constructions. High-strength thin facings combined with lightweight thick core can offer a highly efficient structure when careful consideration is given to practical proportions between facings and core, edge design details, and manufacturing techniques. This paper discusses design approaches to relatively thick-core sandwich constructions. 'A large cylindrical structure subjected to axial compression loading and panel-type structures requiring low deflection under transverse loads are briefly analyzed. The selection of structural adhesives for thick-core structures and manufacturing considerations also are discussed.

SANDWICH CONSTRUCTION↗
NASA NTRS1978

Rub tolerance evaluation of two sintered NiCrAl gas path seal materials

Two strength level variations of sintered NiCrAl (about 40 percent dense), candidate high pressure turbine seal materials, were subject to rub tolerance testing against AM 355 steel blade tips. The high strength material (17 N/sq mm tensile strength) showed frictional and radial loads that were 20 to 50 percent higher than those measured for the low strength material (15.5 N/ sq mm tensile strength). Measured wear to the AM 355 blade tips was not significantly different for the two sintered NiCrAl seal materials. Wear of the sintered NiCrAl was characterized by material removal to a depth greater than the depth to which blade tips were driven into the seal, indicating self-erosion effects.

Bill, R. C.↗
NASA NTRS1989

Microsandwich Honeycombs

In new type of honeycomb panel called "microsandwich honeycomb," walls filled with solid plastic foam reinforced with microspheres. Have compressive and shear strengths 50 to 70 percent greater than those of conventional, unfilled honeycombs of comparable dimensions and densities. Foam and hollow microspheres add little to weight but increase strength substantially. Useful in aircraft, automotive, and marine structures in which high strength and low weight important.

Bhat, Balakrishna↗
NASA NTRS1991

Effect of a prior stretch on the aging response of an Al-Cu-Li-Ag-Mg-Zr alloy

Recently, a family of Al-Cu-Li alloys containing minor amounts of Ag, Mg, and Zr and having desirable combinations of strength and toughness were developed. The Weldalite (trademark) alloys exhibit a unique characteristic in that with or without a prior stretch, they obtain significant strength-ductility combinations upon natural and artificial aging. The ultra-high strength (approximately 690 MPa yield strength) in the peak-aged tempers (T6 and T8) were primarily attributed to the extremely fine T(sub 1) (Al2CuLi) or T(sub 1)-type precipitates that occur in these alloys during artificial aging, whereas the significant natural aging response observed is attributed to strengthening from delta prime (Al3Li) and GP zones. In recent work, the aging behavior of an Al-Cu-Li-Ag-Mg alloy without a prior stretch was followed microstructurally from the T4 to the T6 condition. Commercial extrusions, rolled plates, and sheets of Al-Cu-Li alloys are typically subjected to a stretching operation before artificial aging to straighten the extrusions and, more importantly, introduce dislocations to simulate precipitation of strengthening phases such as T(sub 1) by providing relatively low-energy nucleation sites. The goals of this study are to examine the microstructure that evolves during aging of an alloy that was stretch after solution treatment and to compare the observations with those for the unstretched alloy.

Kumar, K. S.↗
NASA NTRS2004

Structural Benchmark Testing of Superalloy Lattice Block Subelements Completed

Superalloy lattice block panels, which are produced directly by investment casting, are composed of thin ligaments arranged in three-dimensional triangulated trusslike structures (see the preceding figure). Optionally, solid panel face sheets can be formed integrally during casting. In either form, lattice block panels can easily be produced with weights less than 25 percent of the mass of a solid panel. Inconel 718 (IN 718) and MarM-247 superalloy lattice block panels have been developed under NASA's Ultra-Efficient Engine Technology Project and Higher Operating Temperature Propulsion Components Project to take advantage of the superalloys' high strength and elevated temperature capability with the inherent light weight and high stiffness of the lattice architecture (ref. 1). These characteristics are important in the future development of turbine engine components. Casting quality and structural efficiency were evaluated experimentally using small beam specimens machined from the cast and heat treated 140- by 300- by 11-mm panels. The matrix of specimens included samples of each superalloy in both open-celled and single-face-sheet configurations, machined from longitudinal, transverse, and diagonal panel orientations. Thirty-five beam subelements were tested in Glenn's Life Prediction Branch's material test machine at room temperature and 650 C under both static (see the following photograph) and cyclic load conditions. Surprisingly, test results exceeded initial linear elastic analytical predictions. This was likely a result of the formation of plastic hinges and redundancies inherent in lattice block geometry, which was not considered in the finite element models. The value of a single face sheet was demonstrated by increased bending moment capacity, where the face sheet simultaneously increased the gross section modulus and braced the compression ligaments against early buckling as seen in open-cell specimens. Preexisting flaws in specimens were not a discriminator in flexural, shear, or stiffness measurements, again because of redundant load paths available in the lattice block structure. Early test results are available in references 2 and 3; more complete analyses are scheduled for publication in 2004.

Source record↗
DOE OSTI2023

Ultrasonic characterization of Ti-5Al-5Mo-5V-3Cr

Metastable β titanium alloys such as Ti-5Al-5Mo-5V-3Cr are of increasing interest due to their excellent corrosion resistance, high strength, and in particular, the ability to manipulate microstructure to a high degree to control the mechanical properties of the material. It is therefore important to consider how this manipulation of mechanical properties will affect the inspection of this material with ultrasonic testing both for the purposes of flaw detection and material characterization. The connection between material properties and ultrasonic characterization techniques will be discussed and then dissected in the context of Ti-5553. This metastable alloy was shown to exhibit remarkable variation in microstructure as well as ultrasonic velocity and attenuation demonstrating these techniques as potential candidates for characterizing Ti-5553 and Ti-5553 as a good candidate for aiding in future studies aimed at learning more about the role of secondary phases in ultrasonic wave propagation.

Sunderman, Ruth↗
DOE OSTI2022

Extreme hardness at high temperature with a lightweight additively manufactured multi-principal element superalloy

Materials are needed that can tolerate increasingly harsh environments, especially ones that retain high strength at extreme temperatures. Higher melting temperature alloys, like those consisting primarily of refractory elements, can greatly increase the efficiency of turbomachinery used in grid electricity production worldwide. Existing alloys, including Ni- and Co-based superalloys, used in components like turbine blades, bearings, and seals, remain a performance limiting factor due to their propensity, despite extensive optimization efforts, for softening and diffusion-driven elongation at temperatures often well above half their melting point. To address this critical materials challenge, we present results from integrating additive manufacturing and alloy design to guide significant improvements in performance via traditionally difficult-to-manufacture refractory alloys. We present an example of a multi-principal element alloy (MPEA), consisting of five refractory elements and aluminum, that exhibited high hardness and specific strength surpassing other known alloys, including superalloys. The alloy shows negligible softening up to 800°C and consists of four compositionally distinct phases, in distinction to previous work on MPEAs. Density functional theory calculations reveal a thermodynamic explanation for the observed temperature-independent hardness and favorability for the formation of this multiplicity of phases.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Development of Laser Fabricated Ti-6Al-4V

Laser Engineered Net Shaping (LENS) depositions with Ti-6Al-4V gas-atomized powder were accomplished at five different temperatures, ranging from 30 to 400 C, imposed on the base plate. These base plate temperatures were employed in an effort to relieve stresses which develop during the deposition. Warpage of the base plate was monitored. Only a slight decline in warpage was observed as the base plate temperature was increased. Results indicate that substrate temperatures closer to the stress relief minimum of 480 C would relieve deposition stresses, though process parameters would likely need to be modified to compensate for the higher base plate temperature. The compositions of the as-received powder and the LENS deposited material were chemically analyzed. The oxygen content of the LENS material was 0.154 wt.% which is less than the maximum impurity limit of 0.2 percent for commercial Ti-6Al-4V alloys, but is over the limit allowed in ELI grade (0.13 percent). The level of oxygen in the commercial base plate used was only 0.0635 percent. Tensile specimens were machined from the LENS deposited material and tested in tension at room temperature. The ultimate and yield tensile stresses of the LENS material were about 1200 and 1150 MPa respectively, which is about 20 percent higher than the strengths of wrought Ti-6Al-4V. The higher strength of the LENS material was due to its fine structure and high oxygen content. The LENS deposits were not fully dense; voids were frequent at the interfaces between deposited layers. These dispersed sheets of voids were parallel to the longitudinal axis of the resulting tensile specimens. Apparently there was sufficient continuous, fully dense material longitudinally to enable the high strengths. Ductility was low in the LENS material. Percent elongation at failure in the LENS material was near 4 percent, which is less than half of what is usually expected from Ti-6Al-4V. The low ductility was caused by high oxygen levels, and the presence of voids. It is likely that the relatively high scan speeds used in our depositions contributed to the lack of full density in our LENS material.

deGroh, Henry C., III↗
DOE OSTI2021

Tamped Richtmyer–Meshkov Instability Experiments to Probe High-Pressure Material Strength

Abstract Dynamic interface instabilities such as Rayleigh–Taylor, Kelvin–Helmholtz, and Richtmyer–Meshkov are important in a number of physical phenomena. Besides meriting study because of their role in natural events and man-made applications, they can also be used to study constitutive properties of materials in extreme conditions. Both RTI and RMI configurations have been used to study the strength of solids at high strain rates, though RMI has largely been limited to zero or ambient pressure. Recently, advances in imaging have allowed tamped RMI experiments to be performed in which the pressure is maintained above ambient. In this study, we examine the tamped RMI for determining material strength. Through simulation, we explore the behavior of the jetting material and examine the sensitivity of jetting to material properties. We identify simple scaling laws that relate the key physical parameters controlling jetting, which are compared to previous results from the literature. We use these scaling law and other considerations to examine issues associated with tamped RMI experiments.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Creep Testing of Vectran Yarn

NASA and industry are developing inflatable space structures to provide deployable habitable volumes for future exploration missions in space and on the surface of the Moon and Mars. These structures must withstand the constant pressure loading of multi-year missions. These missions therefore require excellent creep resistance in the constituent cordage and webbings that provide the primary structure of the vessel, which is typically constructed using high-strength synthetic materials such as Vectran. Real-time and accelerated creep testing of Vectran webbings has been performed at NASA Langley Research Center (LaRC), however, acceptable correlation between the results of the two approaches has not yet been achieved. Given the additional complexity of the webbing architecture, creep testing at the yarn level is being studied to reduce the number of interacting properties and focus on the core creep behavior to see if better correlation can be achieved between real-time and accelerated tests. To achieve this objective a creep test stand that is able to support simultaneous testing of five Vectran yarns had been previously designed and built. The test stand utilizes two clamp-wrap grips to mount the yarn and has a 10:1 load ratio, via a lever-arm, henceforth, known as the lever-arm test stand. Real-time creep testing (without measuring the strain of the yarn) in this fixture produces yarn ruptures in the gauge section. However, a large scatter in the times to failure was seen in the results across multiple loading conditions. For example, a test at 70% of the ultimate tensile strength (UTS) was found to have specimens that failed within a matter of hours and others that took over 6 weeks to fail. Prior test data on Vectran webbings had indicated high variability in the material strength, leading to higher than average scatter in the creep testing of webbings, which could translate to the scatter in creep behavior at the yarn level as well. However, there was still the possibility that the lever-arm test stand was causing the high scatter in data; specifically, due to potential variability in the loading of each specimen. Therefore, an additional creep test setup was designed and built to attempt to determine if the large scatter in the results was due to inherent material properties, the lever-arm test stand, or both. The newly designed creep test stand, henceforth known as the conventional test stand, utilized the more typical method for creep testing which involved hanging a weight from the yarn with no additional load amplification. The conventional test stand was designed and fabricated in-house at LaRC. High speed cameras were used to validate that the specimens in the conventional test stand failed in the gauge section. Once it was determined that the conventional test stand would provide valid failures in the gauge section, creep tests on the Vectran yarns were run to compare to the lever-arm test stand results. Preliminary results for a 70% UTS creep test have some specimens failing within a number of hours and some failing in excess of 6 weeks. These results are similar to those seen on the lever-arm test stand, pointing towards a large variability inherent in the material. The poster/presentation will focus on the design, fabrication, and validation of the conventional test stand as well as present preliminary results comparing the creep data from the conventional and lever-arm test stands

creep testing↗
NASA NTRS1966

Development of high pressure gas systems

This paper presents a report on the latest advances and technology in the design, construction, testing, and operation of high pressure gas bimetallic pipe systems and high pressure gas tube fittings facilitating greater alinement and manufacturing tolerances, and the supercleaning of high pressure gas systems under field conditions. The following specific topics are discussed: - Analysis of noncorrosive steels versus bimetallic, high strength steels - Analysis of various protective finishes versus bimetallic piping - Testing of high pressure systems - Pipe liner adhesion properties under varying operating conditions - Modified flared tube fittings taking into account pressure ranges, materials, costs involved in manufacture, various methods employed to permit sealing of the fitting while meeting cleanliness requirements - Cleaning requirements appertaining to high pressure gas systems and a discussion of investigations on the effects of velocity and temperature as related to various cleaning chemicals. The presentation concludes with a discussion on the possible applications of materials and methods in commercial industry.

Fitting↗
NASA NTRS1997

High-Flux, High-Temperature Thermal Vacuum Qualification Testing of a Solar Receiver Aperture Shield

As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.

Kerslake, Thomas W.↗
NASA NTRS1991

Compatibility of potential reinforcing ceramics with Ni and Fe aluminides

There is a great deal of interest in the possible utilization of intermetallic compounds in advanced high temperature gas turbine engines. These compounds exhibit a variety of promising properties, including reasonable strength, high melting points, relatively low densities, and good corrosion resistance. However, in general, they also show limited ductilities and toughness, and less than optimum creep strengths at elevated temperatures. In addition, in applications involving advanced gas turbine engines, it is often necessary for candidate materials to have large elastic moduli. The present study is part of a program whose objective is to identify a high temperature fiber reinforced composite. The approach adopted was to fabricate laboratory samples of the combinations of materials considered by Misra, in order to determine the extent to which the thermodynamic calculations can predict phase stability. As many of the ceramic phases considered are not currently available in fiber form, they were added as particulates to the alloy matrices. The ways in which the materials were produced and evaluated are described.

Clark, William A. T.↗
DOE OSTI2023

Strength distributions of laminated FeNi-based metal amorphous nanocomposite ribbons

Metal Amorphous Nanocomposite (MANC) materials offer low losses at high magnetic switching frequency, enabling high power density motors with increased rotational speed. While MANCs have high strength, they are brittle. The use of motor components such as a rotor consisting of brittle material presents a reliability concern. Here, a promising MANC alloy is subjected to tensile tests and failure is observed with high-speed photography. A method is developed to prepare tensile specimens of laminated MANC and epoxy layers, simulating the stacking of an epoxy-impregnated tape-wound core. Tensile tests are conducted for single layer ribbon and for five- and ten-layer stacks of laminated material with thin layers of thermosetting epoxy. Failure distributions are shown to have increasing Weibull modulus with increasing layer count. The composite MANC material system is modeled using chain-of-bundles models. Using a k-failure model, we show that single ribbon strength distribution data can be used to predict well the failure distribution of laminated stacks. The agreement occurs when the assumed ineffective length, over which load is recovered in a failed layer, is comparable to the observed interlaminar separation length.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Yield strength prediction of high-entropy alloys using machine learning

Yield strength at high temperature is an important parameter in the design and application of high entropy alloys (HEAs). However, the experimental measurement of yield strength at high temperature is quite costly, complicated, and time-consuming. Therefore, it is essential to identify and apply a robust method for the accurate prediction of yield strength at high temperature from the available experimental and simulation data. In this study, for the first time, a machine learning (ML) method based on the regression technique of random forest (RF) regressor is used to predict the yield strength of HEAs at the desired temperature. Further, the yield strengths of MoNbTaTiW and HfMoNbTaTiZr at 800 °C and 1200 °C, are predicted using the RF regressor model. We find that the results are consistent with the experimental reports, showing that the RF regressor model predicts the yield strength of HEAs at the desired temperatures with high accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗