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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Fracture Mechanics Testing of Titanium 6AL-4V in AF-M315E

The Green Propellant Infusion Mission (GPIM) will demonstrate the performance of AF-M315E monopropellant on orbit. Flight certification requires a safe-life analysis of the titanium alloy fuel tank to ensure inherent processing flaws will not cause failure during the design life of the tank. Material property inputs for this analysis require testing to determine the stress intensity factor for environment-assisted cracking (KEAC) of Ti 6Al-4V in combination with the AF-M315E monopropellant. Testing of single-edge notched, or SE(B), specimens representing the bulk tank membrane and weld material were performed in accordance with ASTM E1681. Specimens with fatigue pre-cracks were loaded into test fixtures so that the crack tips were exposed to AF-M315E at 50 C for a duration of 1,000 hours. Specimens that did not fail during exposure were opened to inspect the crack surfaces for evidence of crack growth. The threshold stress intensity value, KEAC, is the highest applied stress intensity that produced neither a failure of the specimen during the exposure nor showed evidence of crack growth. The threshold stress intensity factor for environment-assisted cracking of the Ti 6Al-4V forged tank material was found to be at least 22 ksi√in and at least 31 ksi√in for the weld material when exposed to AF-M315E monopropellant.

AF-M315E↗
NASA NTRS2020

Characterization of SiC/SiC Composites Subjected to Sequential Tensile Creep and Dwell Fatigue in Air under Thermal Gradient Conditions

Uncoated SiC/SiC composites, with 2D and 3D fiber architectures, were investigated under steady state thermal gradient conditions with sequential tensile creep and dwell fatigue. Melt infiltration (MI), chemical vapor infiltration (CVI), polymer impregnation and pyrolysis (PIP), and hybrid (CVI and PIP) techniques were used to fabricate ceramic matrix composites (CMCs) with a 2D balanced fiber architecture. CMCs with 3D fiber weaves were also fabricated using MI and hybrid methods. Steady state through the thickness thermal gradients were generated for the tensile specimens using laser heating on the front (hot side) and forced air cooling on the back (cold side). Hot side and cold side temperatures of 2400 and 2200 °F, respectively, were used for testing CMCs fabricated with the MI process, whereas hot side and cold side temperatures of 2700 and 2400 °F, respectively, were used for CMCs fabricated with CVI, PIP, and hybrid processes. Each CMC specimen was initially tested under tensile creep at 69 MPa (10 ksi) for 80 hours, which was then followed by tensile dwell fatigue testing at a maximum stress of 69 MPa (10 ksi) for another 80 hours for a total of 160 hours. This type of sequential tensile creep followed by tensile dwell fatigue testing was performed to ascertain the integrity of uncoated CMCs under steady state thermal gradient conditions. Tensile creep and dwell fatigue test results, generated under steady state thermal gradient conditions on different types of SiC/SiC composites, are compared with corresponding creep behaviors observed under isothermal conditions to determine the influence of both monotonic creep (static fatigue) and dwell fatigue on accumulated strains and deformation behaviors of the CMCs.

Kalluri, Sreeramesh↗
NASA NTRSDate not supplied

Fracture Mechanics Testing of Titanium 6AL-4V in LMP-103S Propellant

Propellant tank safe-life analysis is a spacecraft propulsion subsystem Launch Range processing requirement. The material property inputs for the safe-life analysis include the stress intensity factor for environment-assisted cracking (KEAC). The KEAC for titanium alloy Ti 6Al-4V in LMP-103S propellant was determined experimentally using an innovative test method following ASTM E1681, Standard Test Method for Determining Threshold Stress Intensity Factor for Environment-Assisted Cracking of Metallic Materials. This effort was a collaboration between NASA Goddard Space Flight Center and NASA Kennedy Space Center to expose the test specimens in the propellant, while loaded in the test fixtures, for 1000- hour (42 days) at 50°C. Two test rounds have been completed to date; 1) testing mechanically loaded specimens but without propellant and 2) testing mechanically loaded specimens wetted with LMP-103S propellant. The dry test was to evaluate the crack growth without exposure to the LMP-103S propellant, and further assess the un-wetted stress intensity factor for the full 1000-hour duration. The second round of testing included the propellant soak for the requisite 1000- hour at 50°C. Current results show that the threshold intensity factor for environment-assisted cracking (exposed to LMP103S) is 22.5 ksi√in for the bulk material and 36. 2 ksi√in for the weld material. A generic ‘candidate’ tank geometry and material thickness is developed for a damage tolerance of known surface cracks below the nondestructive inspection technique detection limit. Evaluations with and without the use of a threshold intensity factor for environment-assisted cracking is performed for the required 4x propellant tank service life using the software tool NASGRO. SP2024_00239

Green propulsion↗
NASA NTRS1971

Fundamental Mechanisms of Tensile Fracture in Aluminum Sheet Unidirectionally Reinforced with Boron Filament

Results are presented from an experimental research effort to gain a more complete understanding of the physics of tensile fracture in unidirectionally reinforced B-Al composite sheet. By varying the degree of filament degradation resulting from fabrication, composite specimens were produced which failed in tension by the cumulative mode, the noncumulative mode, or by any desired combination of the two modes. Radiographic and acoustic emission techniques were combined to identify and physically describe a previously unrecognized fundamental fracture mechanism which was responsible for the noncumulative mode. The tensile strength of the composite was found to be severely limited by the noncumulative mechanism which involved the initiation and sustenance of a chain reaction of filament fractures at a relatively low stress level followed by ductile fracture of the matrix. The minimum average filament stress required for initiation of the fracture mechanism was shown to be approximately 170 ksi, and appeared to be independent of filament diameter, number of filament layers, and the identity of the matrix alloy.

Herring, H. W.↗
NASA NTRS1972

Fundamental mechanisms of tensile fracture in aluminum sheet undirectionally reinforced with boron filament

Results are presented from an experimental study of the tensile-fracture process in aluminum sheet unidirectionally reinforced with boron filament. The tensile strength of the material is severely limited by a noncumulative fracture mechanism which involves the initiation and sustenance of a chain reaction of filament fractures at a relatively low stress level. Matrix fracture follows in a completely ductile manner. The minimum filament stress for initiation of the fracture mechanism is shown to be approximately 1.17 GN/sq m (170 ksi), and appears to be independent of filament diameter, number of filament layers, and the strength of the filament-matrix bond. All the commonly observed features of tensile fracture surfaces are explained in terms of the observed noncumulative fracture mechanism.

Herring, H. W.↗
NASA NTRS1972

Low void content autoclave molded titanium alloy and polyimide graphite composite structures.

This paper discusses a resin developed for use in autoclave molding of polyimide graphite composite stiffened, titanium alloy structures. Both primary and secondary bonded structures were evaluated that were produced by autoclave processing. Details of composite processing, adhesive formulary, and bonding processes are provided in this paper, together with mechanical property data for structures. These data include -65 F, room temperature, and 600 F shear strengths; strength retention after aging; and stress rupture properties at 600 F under various stress levels for up to 1000 hours duration. Typically, shear strengths in excess of 16 ksi at room temperature with over 60% strength retention at 600 F were obtained with titanium alloy substrates.

Vaughan, R. W.↗
NASA NTRS1972

Plane strain fracture toughness tests on 2.4 and 3.9-inch-thick maraging steel specimens at various yield strength levels.

Tests of bend and compact specimens were conducted according to ASTM Tentative Method E 399-70T on a 200 grade maraging steel over a range of yield strengths from 123 to 234 ksi. The toughness of any given yield strength level was greater for the overaged condition than for the underaged. Some results which met the specimen size requirements of the method were distinctly lower than corresponding results from larger specimens. Inconsistencies in both validation and invalidation of results by the requirement for linearity of the test record were also noted.

Fisher, D. M.↗
NASA NTRS1972

Investigation of the plastic fracture of high strength steels

An investigation of the plastic fracture process to improve tensile strength in high strength steels is presented. Two generic types of steels are considered: a quenched and tempered grade and a maraging grade, in order to compare two different matrix microstructures. Each type of steel was studied in commercial grade purity and in special melted high purity form, low in residual and impurity elements. The specific alloys dealt with include AISI 4340 and 18 Ni, 200 grade maraging steel, both heat treated to the same yield strength level of approximately 200 ksi.

Cox, T. B.↗
NASA NTRS1973

Filament-wound vessel from an organic fiber-epoxy system.

We evaluated the PRD-49-III fiber by winding 4-in. vessels in an epoxy matrix. From over 130 vessels of various designs, the best average vessel performance factor (PV/W) based on fiber was 2,500,000 in.; based on the composite it was 1,800,000 in. The highest average fiber-failure stress was 446 ksi. It is evident that for shell structures that involve minimal shear loading this fiber/epoxy material system is indeed very attractive.

Chiao, T. T.↗
NASA NTRS1973

High temperature, low-cycle fatigue of copper-base alloys in argon. Part 1: Preliminary results for 12 alloys at 1000 F (538 C)

Short-term tensile evaluations at room temperature and 538 C and low-cycle fatigue evaluations at 538 C are presented for the following materials: Zirconium copper-annealed, Zirconium copper-1/4 hard, Zirconium copper-1/2 hard, Tellurium copper-1/2 hard, Chromium copper-SA and aged, OFHC copper-hard, OFHC copper-1/4 hard, OFHC copper-annealed, Silver-as drawn, Zr-Cr-Mg copper-SA, CW and aged, Electroformed copper-30-35 ksi, and Co-Be-Zr- copper-SA, aged. A total of 50 tensile tests and 76 low-cycle fatigue tests were performed using a strain rate of 0.2 percent per second.

Conway, J. B.↗
NASA NTRS1973

Evaluation of polyimide/glass fiber composites for construction of light weight pressure vessels for cryogenic propellants

The application of polyimide resin as a matrix for glass filament-wound thin metal-lined pressure vessels was studied over a temperature range of (minus) 320 to 600 F. Keramid 601 polyimide was found to perform quite well over the entire range of temperature. Hoop stress values of 425 ksi were determined at 75 F which is equivalent to epoxy resin in similar structures. At -320 and 600 F, 125 and 80% of this strength was retained. Thermal ageing at 500 F for up to 50 hours was studied with severe reduction in strength, but there is evidence that this reduction could be improved. Another polyimide resin studied was P10PA which was found to have processing characteristics inappropriate for filament-winding. NOL ring tensile and shear data was determined from both resins with S-glass. Pressure vessel design, fabrication and test procedures are described in detail.

Petker, I.↗
NASA NTRS1973

Evaluation of shuttle solid rocket booster case materials. Corrosion and stress corrosion susceptibility of several high temperature materials

Candidate alloys for the Shuttle Solid Rocket Booster (SRB) case were tested under simulated service conditions to define subcritical flaw growth behavior under both sustained and cyclic loading conditions. The materials evaluated were D6AC and 18 Ni maraging steel, both heat treated to a nominal yield strength of 1380 MN/sq m (200 ksi). The sustained load tests were conducted by exposing precracked, stressed specimens of both alloys to alternate immersion in synthetic sea water. It was found that the corrosion and stress corrosion resistance of the 18 Ni maraging steel were superior to that of the D6AC steel under these test conditions. It was also found that austenitizing temperature had little influence on the threshold stress intensity of the D6AC. The cyclic tests were conducted by subjecting precracked surface-flawed specimens of both alloys to repeated load/thermal/environmental profiles which were selected to simulate the SRB missions. It was found that linear removal operations that involve heating to 589 K (600 F) cause a decrease in cyclic life of D6AC steel relative to those tests conducted with no thermal cycling.

Pionke, L. J.↗
NASA NTRS1974

Stress corrosion cracking susceptibility of 18 Ni maraging steel

The stress corrosion cracking (SCC) resistance of 18Ni maraging steel (grades 200, 250, 300, and 350) was determined in 3.5 percent salt (NaCl) solution, synthetic sea water, high humidity, and outside MSFC atmosphere. All grades of the maraging steel were found to be susceptible to SCC in varying degrees according to their strengths, with the lowest strength steel (grade 200) being the least susceptible and the highest strength steel (grade 350), the most susceptible to SCC. The SCC resistance of 250 grade maraging steel was also evaluated in salt and salt-chromate solutions using fracture mechanics techniques. The threshold value, K sub SCC, was found to be approximately 44 MN/sq m square root m, (40 ksi square root in.) or 40 percent of the K sub Q value.

Humphries, T. S.↗
NASA NTRS1974

An investigation of the plastic fracture of AISI 4340 and 18 nickel - 200 grade maraging steels

The mechanisms of plastic fracture (dimpled rupture) in high-purity and commercial 18 Ni, 200 grade maraging steels and quenched and tempered AISI 4340 steels have been studied. Plastic fracture takes place in the maraging alloys through void initiation by fracture of titanium carbo-nitride inclusions and the growth of these voids until impingement results in coalescence and final fracture. The fracture of AISI 4340 steel at a yield strength of 200 ksi occurs by nucleation and subsequent growth of voids formed by fracture of the interface between manganese sulfide inclusions and the matrix. The growth of these inclusion-nucleated voids is interrupted long before coalescence by impingement, by the formation of void sheets which connect neighboring sulfide-nucleated voids.

Cox, T. B.↗
NASA NTRS1974

The resistance to embrittlement by a hydrogen environment of selected high strength iron-manganese base alloys

Fe-16Mn and Fe-25Mn base alloys, which had been cold worked to yield strength levels of 201 and 178 KSI, were resistant to degradation of mechanical properties in a one atmosphere hydrogen environment at ambient temperature under the loading conditions employed in this investigation. Transmission electron microscopy established that bands of epsilon phase martensite and fcc mechanical twins were formed throughout the fcc matrix when these alloys were cold worked. In the cold worked alloys a high density of crystal defects were observed associated with both types of strain induced structures, which should contribute significantly to the strengthening of these alloys. High strength iron base alloys can be produced which appear to have some resistance to degradation of mechanical properties in a hydrogen environment under certain conditions.

Benson, R. B., Jr.↗
NASA NTRS1976

Tungsten wire-nickel base alloy composite development

Further development and evaluation of refractory wire reinforced nickel-base alloy composites is described. Emphasis was placed on evaluating thermal fatigue resistance as a function of matrix alloy composition, fabrication variables and reinforcement level and distribution. Tests for up to 1,000 cycles were performed and the best system identified in this current work was 50v/o W/NiCrAlY. Improved resistance to thermal fatigue damage would be anticipated for specimens fabricated via optimized processing schedules. Other properties investigated included 1,093 C (2,000 F) stress rupture strength, impact resistance and static air oxidation. A composite consisting of 30v/o W-Hf-C alloy fibers in a NiCrAlY alloy matrix was shown to have a 100-hour stress rupture strength at 1,093 C (2,000 F) of 365 MN/square meters (53 ksi) or a specific strength advantage of about 3:1 over typical D.S. eutectics.

Brentnall, W. D.↗
NASA NTRS1976

Detection of tightly closed flaws by nondestructive testing (NDT) methods in steel and titanium

X-radiographic, liquid penetrant, ultrasonic, eddy current and magnetic particle testing techniques were optimized and applied to the evaluation of 4340 steel (180 KSI-UTS) and 6Al-4V titanium (STA) alloy specimens. Sixty steel specimens containing a total of 176 fatigue cracks and 60 titanium specimens containing a total of 135 fatigue cracks were evaluated. The cracks ranged in length from .043 cm (0.017 inch) to 1.02 cm (.400 inch) and in depth from .005 cm (.002 inch) to .239 cm (.094 inch) for steel specimens. Lengths ranged from .048 cm (0.019 inch) to 1.03 cm (.407 inch) and depths from 0.010 cm (.004 inch) to .261 cm (0.103 inch) for titanium specimens. Specimen thicknesses were nominally .152 cm (0.060 inch) and 0.635 cm (0.250 inch) and surface finishes were nominally 125 rms. Specimens were evaluated in the "as machined" surface condition, after etch surface and after proof loading in a randomized inspection sequence.

Rummel, W. D.↗