New cobalt alloys have high-temperature strength and long life in vacuum environments
Cobalt refractory metal alloys combine sheet formability with high temperature strength and low material loss in vacuum.
Ashbrook, R. L.↗
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Results for “Formability”
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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The development of magnesium-lithium alloys for structural applications final technical report
Magnesium-lithium alloy structures - thin wall tubing extrusion, metallic coating deposition, machinability, chemical milling, brazing, sheet formability, corrosion behavior and protection
MILLING↗
Weldable aluminum alloy has improved mechanical properties
Weldable aluminum alloy has good resistance to stress-corrosion cracking, shows unchanged strength and formability after storage at room temperature, and can be pre-aged, stretched, and aged. Since toxic fumes of cadmium oxide are evolved when the new alloy is welded, adequate ventilation must be provided.
Westerlund, R. W.↗
Development of structural test articles from magnesium-lithium and beryllium
Study on the fabrication and testing of a magnesium-lithium box beam shows the formability and machinability characteristics of that alloy to be excellent. Results of forming tests for shrink and stretch flanges show values for both flange heights that may be used in future beryllium design.
Alario, R.↗
Applications of composite materials in space vehicle structures
Filamentary composite materials for space vehicles structural design, noting mass reduction, strength, foldability, formability, etc
Heldenfels, R. R.↗
Development of dispersion-strengthened Ni-Cr-ThOz alloys for the space shuttle thermal protection system
Manufacturing processes were developed for TD-NiCr providing small sheet (45 x 90 cm), and larger sheet (60 x 150 cm) and foil. The alternate alloy, DS-NiCr, was produced by pack-chromizing Ni-ThO2 sheet. Formability criteria are being established for basic sheet forming processes, which are brake forming, corrugation forming, joggling, dimpling, and beading. Resistance spot welding (fusion and solid state), resistance seam welding, solid state diffusion welding, and brazing are included in the joining programs. Major emphasis is centered on an Al-modified Ni-Cr-ThO2 alloy development. These alloys, containing 3 to 5% Al, form the protective Al2O3 scale. This enhances oxidation resistance under reentry conditions. Both TD-NiCrAl and DS-NiCrAl alloys are included. A tentative composition of Ni-16Cr-3.5Al-2ThO2 was selected based on oxidation resistance and fabricability.
Blankenship, C. P.↗
Development of dispersion-strengthened Ni-Cr-ThO2 alloys for the space shuttle thermal protection system.
An improved manufacturing process has been developed for TD-NiCr that provides sheet of improved quality, better gage control, and reproducible properties. A standard manufacturing process has been developed for the alternate alloy, DS-NiCr, produced by pack-chromizing Ni-2ThO2 sheet. Extension of forming and joining technology for TD-NiCr is in process. Formability criteria are being established for basic sheet forming processes related to the manufacture of Shuttle TPS panels. They include brake forming, corrugation forming, joggling, dimpling, and beading. Joining processes applicable to TPS panels are being optimized with emphasis on establishment of joint efficiencies. Resistance spot welding (fusion and solid state), resistance seam welding, solid-state diffusion welding, and brazing are included in the joining programs. Development of improved manufacturing technology for TD-NiCr fasteners is also being accomplished. Mechanical and physical properties of TD-NiCr are being characterized to provide design-allowable data.
Blankenship, C. P.↗
Development of forming and joining technology for TD-NiCr sheet
Forming joining techniques and properties data were developed for thin-gage TD-NiCr sheet in the recrystallized and unrecrystallized conditions. Theoretical and actual forming limit data are presented for several gages of each type of material for five forming processes: brake forming, corrugation forming, joggling, dimpling and beading. Recrystallized sheet can be best formed at room temperature, but unrecrystallized sheet requires forming at elevated temperature. Formability is satisfactory with most processes for the longitudinal orientation but poor for the transverse orientation. Dimpling techniques require further development for both material conditions. Data on joining techniques and joint properties are presented for four joining processes: resistance seam welding (solid-state), resistance spot welding (solid-state), resistance spot welding (fusion) and brazing. Resistance seam welded (solid-state) joints with 5t overlap were stronger than parent material for both material conditions when tested in tensile-shear and stress-rupture. Brazing studies resulted in development of NASA 18 braze alloy (Ni-16Cr-15Mo-8Al-4Si) with several properties superior to baseline TD-6 braze alloy, including lower brazing temperture, reduced reaction with Td-Ni-Cr, and higher stress-rupture properties.
Torgerson, R. T.↗
Effect of TMP variables upon structure and properties in ODS alloy HDA 8077 sheet
The effects of oxide content level and variations in thermomechanical processing upon the final structure and properties of HDA 8077 sheet have been systematically examined. It was found that creep strength and formability are substantially influenced by both oxide content and TMP schedule. Variations in creep properties obtained appear to correlate with observed microstructures.
Rothman, M. F.↗
Effect of storing B-staged graphite/polyimide on fabrication of structural elements
Graphite/polyimide structural elements have been successfully fabricated by forming and curing B-staged Celion 6000/PMR-15 and Celion 6000/LaRC-160 laminates in heated matched metal tooling. The B-staged laminates were subjected to storage for various periods of time up to six months at ambient shop conditions and high humidity prior to fabrication into structural elements to determine the processability of the graphite/polyimide after exposure to these conditions. Changes in processability were monitored by measuring flexure and interlaminar shear strengths, glass transition temperature, moisture content, and formability of the B-staged laminates. No significant change in the processability of either Celion 6000/PMR or Celion 6000/LaRC-160 was recorded indicating that after B-staging the graphite/polyimide laminates can be stored for extended periods of time in normal shop and high humidity environments and then be fabricated into defect-free structural elements in heated platen presses.
Baucom, R. M.↗
Elevated temperature behavior of superplastically formed/weld-brazed titanium compression panels having advanced shaped stiffeners
The 316 C (600 F) buckling behavior of superplastically formed/weld-brazed titanium compression panels having advanced shaped stiffeners was investigated. Fabrication of the advanced shaped stiffeners was made possible by the increased formability afforded by the superplasticity characteristics of the titanium alloy Ti-6Al-4V. Stiffeners having the configurations of a conventional hat, a beaded web, a modified beaded web, a ribbed web, and a stepped web were investigated. The data from the panel tests include load-shortening curves, local buckling strengths, and failure loads. The superplastic formed/weld-brazed panels with the ribbed web and stepped web stiffeners developed 25 and 27 percent higher buckling strengths at 316 C (600 F) than panels with conventionally shaped stiffeners. The buckling load reductions for panels tested at 316 C (600 F), compared with panels tested at room temperature, were in agreement with predictions based on titanium material property data. The advantage that higher buckling loads can be readily achieved by superplastically forming of advanced stiffener shapes was demonstrated. Application of these advanced stiffener shapes offers the potential to achieve substantial weight savings in aerospace vehicles.
Royster, D. M.↗
LDR segmented mirror technology assessment study
In the mid-1990s, NASA plans to orbit a giant telescope, whose aperture may be as great as 30 meters, for infrared and sub-millimeter astronomy. Its primary mirror will be deployed or assembled in orbit from a mosaic of possibly hundreds of mirror segments. Each segment must be shaped to precise curvature tolerances so that diffraction-limited performance will be achieved at 30 micron (nominal operating wavelength). All panels must lie within 1 micron on a theoretical surface described by the optical precipitation of the telescope's primary mirror. To attain diffraction-limited performance, the issues of alignment and/or position sensing, position control of micron tolerances, and structural, thermal, and mechanical considerations for stowing, deploying, and erecting the reflector must be resolved. Radius of curvature precision influences panel size, shape, material, and type of construction. Two superior material choices emerged: fused quartz (sufficiently homogeneous with respect to thermal expansivity to permit a thin shell substrate to be drape molded between graphite dies to a precise enough off-axis asphere for optical finishing on the as-received a segment) and a Pyrex or Duran (less expensive than quartz and formable at lower temperatures). The optimal reflector panel size is between 1-1/2 and 2 meters. Making one, two-meter mirror every two weeks requires new approaches to manufacturing off-axis parabolic or aspheric segments (drape molding on precision dies and subsequent finishing on a nonrotationally symmetric dependent machine). Proof-of-concept developmental programs were identified to prove the feasibility of the materials and manufacturing ideas.
Krim, M.↗
Low-Temperature Forming of Beta Titanium Alloys
Low cost methods for titanium structural fabrication using advanced cold-formable beta alloys were investigated for application in a Mach 2.7 supersonic cruise vehicle. This work focuses on improving processing and structural efficiencies as compared with standard hot formed and riveted construction of alpha-beta alloy sheet structure. Mechanical property data and manufacturing parameters were developed for cold forming, brazing, welding, and processing Ti-15V-3Cr-3Sn-3Al sheet, and Ti-3Al-8V-6Cr-4Zr on a more limited basis. Cost and structural benefits were assessed through the fabrication and evaluation of large structural panels. The feasibility of increasing structural efficiency of beta titanium structure by selective reinforcement with metal matrix composite was also explored.
Kaneko, R. S.↗
Crystallization, Optical and Chemical Properties of Fluoride Glasses
Fluoride glasses have great promise as infrared optical components, especially fibers, because they are transparent to 8 micrometers and higher. In order to optimize properties, different glass compositions are needed. Some are hard to form in a container, and may possibly be formable in a containerless furnace. Understanding of crystallization with and without a container could lead to glasses with optimum properties. Chemical durability (attack by water) can limit or extend the applicability of fluoride glasses. Progress to date is given.
Doremus, R. H.↗
Edge-restraint deformation processing of aluminides and other powders
The novel, 'edge-restraint rolling' method has been developed in order to facilitate the thickness reduction of brittle, high strength alloys to the degree of thin plates or sheets, by first hot-compacting the prealloyed powders into billets and conducting the thickness reduction in a series of reheats and roll passes. Attention is presently given to the cases of equiatomic aluminide FeAl, (Ni,Fe)3Al, and an Al-Fe alloy. The flat-rolled products thus obtained may lead to the development of components not otherwise formable for powerplant and other aerospace applications.
Bhattacharyya, S.↗
Monocoque structure for the SKITTER three-legged walker
The SKITTER 2 design is a monocoque version of the proposed lunar three-legged walker. By the definition of monocoque, the body and legs are a shell with no internal ribbing or supports added for absorbing stresses. The purpose of the monocoque is to encase the elements used for power transmission, power supply, and control of the motion. The material for the structure is a vinyl ester resin, Derakane 8084. This material is easily formable and locally obtainable. The body consists of a hexagonally shaped cylinder with truncated hexagonal pyramids on the top and botton. The legs are eight inch diameter cylinders. The legs are comprised of a tibia section and a femur section. The SKITTER 2 is powered by six actuators which provide linear forces that are transformed into rotary torques by a series of chains and sprockets. The joints connect the femur to the body and the tibia to the femur. Surrounding the joints are flexible rubber hoses that fully encase the chains and sprockets. The SKITTER 2 is capable of walking upside down, righting itself after being overturned, and has the ability to perform in many environments. Applications for this walker include lunar transport or drilling, undersea exploration, and operation in severe surroundings such as arctic temperatures or high radiation.
Bansek, Robert N.↗
Continuation of tailored composite structures of ordered staple thermoplastic material
The search for the cost effective composite structure has motivated the investigation of several approaches to develop composite structure from innovative material forms. Among the promising approaches is the conversion of a planar sheet to components of complex curvature through sheet forming or stretch forming. In both cases, the potential for material stretch in the fiber direction appears to offer a clear advantage in formability over continuous fiber systems. A framework was established which allows the simulation of the anisotropic mechanisms of deformation of long discontinuous fiber laminates wherein the matrix phase is a viscous fluid. Predictions for the effective viscosities of a hyper-anisotropic medium consisting of collimated, discontinuous fibers suspended in viscous matrix were extended to capture the characteristics of typical polymers including non-Newtonian behavior and temperature dependence. In addition, the influence of fiber misorientation was also modeled by compliance averaging to determine ensemble properties for a given orientation distribution. A design tool is presented for predicting the effect of material heterogeneity on the performance of curved composite beams such as those used in aircraft fuselage structures. Material heterogeneity can be induced during manufacturing processes such as sheet forming and stretch forming of thermoplastic composites. This heterogeneity can be introduced in the form of fiber realignment and spreading during the manufacturing process causing radial and tangential gradients in material properties. Two analysis procedures are used to solve the beam problems. The first method uses separate two-dimensional elasticity solutions for the stresses in the flange and web sections of the beam. The separate solutions are coupled by requiring that forces and displacements match section boundaries. The second method uses an approximate Rayleigh-Ritz technique to find the solutions for more complex beams. Analyses are performed for curved beams of various cross-sections loaded in pure bending and with a uniform distributed load. Preliminary results show that the geometry of the beam dictates the effect of heterogeneity on performance. The role of heterogeneity is larger in beams with a small average radius-to-depth ration, R/t, where R is the average radius of the beam and t is the difference between the inside and outside radii. Results of the anlysis are in the form of stresses and displacements and are compared to both mechanics of materials and numerical solutions obtained using finite element analysis.
Santare, Michael H.↗
Long discontinuous fiber composite structure: Forming and structural mechanics
Cost effective composite structure has motivated the investigation of several new approaches to develop composite structure from innovative material forms. Among the promising new approaches is the conversion of planar sheet to components of complex curvature through sheet forming or stretch forming. In both cases, the potential for material stretch in the fiber direction appears to offer a clear advantage in formability over continuous fiber systems. In the present study, the authors have established a framework which allows the simulation of the anisotropic mechanisms of deformation of long discontinuous fiber laminates wherein the matrix phase is a viscous fluid. The initial study focuses upon the establishment of micromechanics models for prediction of the effective anisotropic viscosities of the oriented fiber assembly in a viscous matrix. Next, the developed constitutive relation is employed through an analogy with incompressible elasticity to exercise the finite element technique for determination of local fiber orientation and laminate thickness after forming. Results are presented for the stretch bending of a curved beam from an arbitrary composite laminate and the bulging of a clamped sheet. Structural analyses are conducted to determine the effect of microstructure on the performance of curved beams manufactured from long discontinuous fiber composites. For the purposes of this study, several curved beams with ideal and non-ideal microstructures are compared for response under pure bending. Material parameters are determined from a separate microstructural analysis.
Pipes, R. B.↗