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NASA NTRS1989

Deformation modeling and constitutive modeling for anisotropic superalloys

A study of deformation mechanisms in the single crystal superalloy PWA 1480 was conducted. Monotonic and cyclic tests were conducted from 20 to 1093 C. Both (001) and near-(123) crystals were tested, at strain rates of 0.5 and 50 percent/minute. The deformation behavior could be grouped into two temperature regimes: low temperatures, below 760 C; and high temperatures, above 820 to 950 C depending on the strain rate. At low temperatures, the mechanical behavior was very anisotropic. An orientation dependent CRSS, a tension-compression asymmetry, and anisotropic strain hardening were all observed. The material was deformed by planar octahedral slip. The anisotropic properties were correlated with the ease of cube cross-slip, as well as the number of active slip systems. At high temperatures, the material was isotropic, and deformed by homogeneous gamma by-pass. It was found that the temperature dependence of the formation of superlattice-intrinsic stacking faults was responsible for the local minimum in the CRSS of this alloy at 400 C. It was proposed that the cube cross-slip process must be reversible. This was used to explain the reversible tension-compression asymmetry, and was used to study models of cross-slip. As a result, the cross-slip model proposed by Paidar, Pope and Vitek was found to be consistent with the proposed slip reversibility. The results were related to anisotropic viscoplastic constitutive models. The model proposed by Walter and Jordan was found to be capable of modeling all aspects of the material anisotropy. Temperature and strain rate boundaries for the model were proposed, and guidelines for numerical experiments were proposed.

Milligan, Walter W.↗

NASA NTRS1986

Life prediction and constitutive models for engine hot section

The purpose of this program is to develop life prediction models for coated anisotropic materials used in gas turbine airfoils. In the program, two single crystal alloys and two coatings are being tested. These include PWA 1480, Alloy 185, overlay coating (PWA 286), and aluminide coating (PWA 273). Constitutive models are also being developed for these materials to predict the time independent (plastic) and time dependent (creep) strain histories of the materials in the lab tests and for actual design conditions. This nonlinear material behavior is particularly important for high temperature gas turbine applications and is basic to any life prediction system. Some of the accomplishments of the program are highlighted.

Swanson, G. A.↗

NASA NTRS2000

Effect of Crystal Orientation on Fatigue Failure of Single Crystal Nickel Base Turbine Blade Superalloys

High Cycle Fatigue (HCF) induced failures in aircraft gas-turbine engines is a pervasive problem affecting a wide range of components and materials. HCF is currently the primary cause of component failures in gas turbine aircraft engines. Turbine blades in high performance aircraft and rocket engines are increasingly being made of single crystal nickel superalloys. Single-crystal Nickel-base superalloys were developed to provide superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys previously used in the production of turbine blades and vanes. Currently the most widely used single crystal turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. PWA1493, identical to PWA1480, but with tighter chemical constituent control, is used in the NASA SSME (Space Shuttle Main Engine) alternate turbopump, a liquid hydrogen fueled rocket engine. Objectives for this paper are motivated by the need for developing failure criteria and fatigue life evaluation procedures for high temperature single crystal components, using available fatigue data and finite element modeling of turbine blades. Using the FE (finite element) stress analysis results and the fatigue life relations developed, the effect of variation of primary and secondary crystal orientations on life is determined, at critical blade locations. The most advantageous crystal orientation for a given blade design is determined. Results presented demonstrates that control of secondary and primary crystallographic orientation has the potential to optimize blade design by increasing its resistance to fatigue crack growth without adding additional weight or cost.

Arakere, Nagaraj K.↗

NASA NTRS1999

1300 K Creep Behavior of [001] Oriented Ni-49Al-1Hf (at.%) Single Crystals

A study of the 1300 K compressive and tensile creep properties of [001]-oriented NiAl-1Hf (D209) single crystals has been undertaken. Neither post homogenization cooling treatment, minor chemical variations within an ingot or from ingot-to-ingot, nor testing procedure had a significant effect on mechanical behavior; however a heat treatment which dissolved the initial G-phase precipitates and promoted formation of Heusler particles led to a strength reduction. Little primary creep was found utilizing direct measurement of strain, and a misorientation of 18 deg from the [001] did not reduce the creep strength. The effects of heat treatments on properties and a comparison of the flow stress-strain rate data to those predicted by the Jaswon-Cottrell solid solution hardening model indicate that the 1300 K strength in NiAl-1Hf single crystals is mainly due to precipitation hardening mechanisms.

Whittenberger, J. Daniel↗

NASA NTRS2012

Rhombohedral cubic semiconductor materials on trigonal substrate with single crystal properties and devices based on such materials

Growth conditions are developed, based on a temperature-dependent alignment model, to enable formation of cubic group IV, group II-V and group II-VI crystals in the [111] orientation on the basal (0001) plane of trigonal crystal substrates, controlled such that the volume percentage of primary twin crystal is reduced from about 40% to about 0.3%, compared to the majority single crystal. The control of stacking faults in this and other embodiments can yield single crystalline semiconductors based on these materials that are substantially without defects, or improved thermoelectric materials with twinned crystals for phonon scattering while maintaining electrical integrity. These methods can selectively yield a cubic-on-trigonal epitaxial semiconductor material in which the cubic layer is substantially either directly aligned, or 60 degrees-rotated from, the underlying trigonal material.

Park, Yeonjoon↗

NASA NTRS1981

Defect chemistry and characterization of (Hg, Cd)Te

Single crystal samples of phosphorus doped Hg sub 0.8 Cd sub 0.2 Te were anneald at temperatures varying from 450 C to 600 C in various Hg atmospheres. The samples were quenched to room temperature from the annealing temperatures. Hall effect and mobility measurements were performed at 77 K on all these samples. The results indicate the crystals to be p type for a total phosphorus concentration of 10 to the 19th power/cu cm in all the samples. The hole concentration at 77 K increases with increasing Hg pressures at 450 C and 500 C contrary to the observation in undoped crystals. Also, at low Hg pressures the concentration of holes in the phosphorus doped crystals is lower than in the undoped crystals. The hole concentration in all the samples is lower than the intrinsic carrier concentration at the annealing temperatures. The hole mobility in the doped crystals is similar to that in the undoped crystals. A defect model according to which phosphorus behaves as a single acceptor interstitially, occupying Te lattice sites while it acts as a single donor occupying Hg lattice sites was established. Equilibrum constants established for the incorporation of all the phosphorus species explain the experimental results

Vydyanath, H. R.↗

NASA NTRS2004

Investigation of Three-Dimensional Stress Fields and Slip Systems for FCC Single Crystal Superalloy Notched Specimens

Metals and their alloys, except for a few intermetallics, are inherently ductile, i.e. plastic deformation precedes fracture in these materials. Therefore, resistance to fracture is directly related to the development of the plastic zone at the crack tip. Recent studies indicate that the fracture toughness of single crystals depends on the crystallographic orientation of the notch as well as the loading direction. In general, the dependence of crack propagation resistance on crystallographic orientation arises from the anisotropy of (i) elastic constants, (ii) plastic deformation (or slip), and (iii) the weakest fracture planes (e.g. cleavage planes). Because of the triaxial stress state at the notch tips, many slip systems that otherwise would not be activated during uniaxial testing, become operational. The plastic zone formation in single crystals has been tackled theoretically by Rice and his co-workers and only limited experimental work has been conducted in this area. The study of the stresses and strains in the vicinity of a FCC single crystal notch tip is of relatively recent origin. We present experimental and numerical investigation of 3D stress fields and evolution of slip sector boundaries near notches in FCC single crystal tension test specimens, and demonstrate that a 3D linear elastic finite element model that includes the effect of material anisotropy is shown to predict active slip planes and sectors accurately. The slip sector boundaries are shown to have complex curved shapes with several slip systems active simultaneously near the notch. Results are presented for surface and mid-plane of the specimens. The results demonstrate that accounting for 3D elastic anisotropy is very important for accurate prediction of slip activation near FCC single crystal notches loaded in tension. Results from the study will help establish guidelines for fatigue damage near single crystal notches.

Arakere, Nagaraj K.↗

NASA NTRS1993

Origin of the Apollo 15 very low Ti green glass. A perspective from the compositional diversity in the very low Ti glasses

The very low Ti green glasses from the Apollo 15 site have intrigued scientists for over 20 years. Their primitive composition has been used to understand magmatic processes and the structure of the moon. The compositional variability observed in the Apollo 15 glass population has long been a point of debate. Initial studies did not recognize the compositional diversity in the glasses. Stolper et al. documented the major element variability and concluded it could not be produced by magmatic processes and therefore concluded that these glasses must be of impact origin. Subsequent studies confirmed a volcanic origin for the glass population and attempted to elucidate magmatic processes to account for its compositional variability. Models that have been proposed for these glasses include the following: (1) the crystallization of single or multiple phases (olivine, pyroxene, Fe metal, immiscible sulfide); (2) the incompatible behavior of Ni and Co during multiple phase crystallization at extremely low fO2; and (3) magma or source mixing. All of these models have problems. Type (1) models appear not to be consistent with recent trace element studies on the glasses; model (2) is dependent on the debatable incompatible behavior of Ni and Co, and, in models of type (3), the origin and nature of mixing models are somewhat unconstrained. This study compares the Apollo 15 green glasses with the very low Ti picritic glasses from other landing sites.

Shearer, C. K.↗

NASA NTRS2005

Prediction of Fretting Crack Location and Orientation in a Single Crystal Nickel Alloy

Fretting is a structural damage mechanism arising between two nominally clamped surfaces subjected to an oscillatory loading. A critical location for fretting induced damage has been identified at the blade/disk and blade/damper interfaces of gas turbine engine turbomachinery and space propulsion components. The high- temperature, high-frequency loading environment seen by these components lead to severe stress gradients at the edge-of-contact that could potentially foster crack growth leading to component failure. These contact stresses drive crack nucleation in fretting and are very sensitive to the geometry of the contacting bodies, the contact loads, materials, temperature, and contact surface tribology (friction). Recently, a high-frequency, high-temperature load frame has been designed for experimentally investigating fretting damage of single crystal nickel materials employed in aircraft and spacecraft turbomachinery. A modeling method for characterizing the fretting stresses of the spherical fretting contact stress behavior in this experiment is developed and described. The calculated fretting stresses for a series of experiments are then correlated to the observed fretting damage. Results show that knowledge of the normal stresses and resolved shear stresses on each crystal plane can aid in predicting crack locations and orientations.

Matlik, J. F.↗

NASA NTRS1985

Constitutive Cyclic Deformation Behavior in Single-crystal and Directionally Solidified SSME High-pressure Fuel Turbopump Airfoil Materials

The major goal of the project is to correlate mechanical properties with microstructural deformation behavior and to develop models for constitutive response under a variety of monotonic and cyclic loading cycles, temperatures, strain levels, strain rates, and environments. Two alloys are being studied as candidate SSME turbine blade materials. The first is PWA 1480, which is a single-crystal alloy whose nominal composition is reported. The second alloy being studied is D.S. Mar-M 246 + Hf. This is a directionally solidified material, and its nominal composition is also reported. The major areas of interest for the two materials will be slightly different. The single-crystal alloy lends itself well to fundamental deformation studies, since resolved shear stresses on slip planes are all known and only one grain is present. The D.S. material presents an excellent opportunity to study the effects of slightly misaligned grains on deformation behavior. The two materials will be studied by using approximately the same test matrix, so a good degree of direct comparison will also be possible.

Milligan, W. W.↗

NASA NTRS1984

Life prediction and constitutive models for engine hot section anisotropic materials

The development of directionally solidified and single crystal alloys is perhaps the most important recent advancement in hot section materials technology. The objective is to develop knowledge that enables the designer to improve anisotropic gas turbine parts to their full potential. Two single crystal alloys selected were PWA 1480 and Alloy 185. The coatings selected were an overlay coating, PWA 286, and an aluminide diffusion coating, PWA 273. The constitutive specimens were solid and cylindrical; the fatigue specimens were hollow and cylindrical. Two thicknesses of substrate are utilized. Specimens of both thickness (0.4 and 1.5 mm) will be coated and then tested for tensile, creep, and fatigue properties.

Swanson, G. A.↗

NASA NTRS1990

Interpretation of satellite-measured bidirectional reflectance from Cirrus cloudy atmospheres

The interpretation of the observed bidirectional reflectance from cirrus cloudy atmospheres is presented. A theoretical model was developed for the computation of the transfer of solar radiation in an anisotropic medium with particular applications to oriented ice crystals in cirrus clouds. In this model, the adding principle for radiative transfer was used with modifications to account for the anisotropy of scattering particles and the associated scattering phase matrix. The single-scattering properties, including the phase function, single-scattering albedo, and extinction cross sections, were used for randomly and horizontally oriented hexagonal ice crystals in radiative transfer computations. The radiative transfer model developed for the cirrus clouds was modified to account for the scattering contributions from the atmosphere and the surface. In order to test the relevance and significance of the ice crystal model for the interpretation of observed bidirectional reflectance from satellites, visible radiances collected on the half hour by the GOES series were selected. The data are calibrated and corrected with the proper filter functions, then navigated to match selected landmark data. A number of clear and cloudy cases during the cirrus IFO of the Fire experiment were chosen for theoretical analyses. The cloud particle shape and size distributions that were taken during satellite overpasses are used in radiative transfer calculations. The sensitivities of the shape, orientation, and size distribution of ice crystals on the reflected intensities at the top of the atmosphere are investigated. Finally, the relative importance of these cloud microphysical properties in the interpretation of satellite bidirectional reflectance are assessed and presented.

Takano, Y.↗

NASA NTRS1991

Estimation of the engineering elastic constants of a directionally solidified superalloy for finite element structural analysis

The temperature-dependent engineering elastic constants of a directionally solidified nickel-base superalloy were estimated from the single-crystal elastic constants of nickel and MAR-MOO2 superalloy by using Wells' method. In this method, the directionally solidified (columnar-grained) nickel-base superalloy was modeled as a transversely isotropic material, and the five independent elastic constants of the transversely isotropic material were determined from the three independent elastic constants of a cubic single crystal. Solidification for both the single crystals and the directionally solidified superalloy was assumed to be along the (001) direction. Temperature-dependent Young's moduli in longitudinal and transverse directions, shear moduli, and Poisson's ratios were tabulated for the directionally solidified nickel-base superalloy. These engineering elastic constants could be used as input for performing finite element structural analysis of directionally solidified turbine engine components.

Abdul-Aziz, Ali↗

NASA NTRS1994

A model predicting the evolution of ice particle size spectra and radiative properties of cirrus clouds. Part 2: Dependence of absorption and extinction on ice crystal morphology

This study builds upon the microphysical modeling described in Part 1 by deriving formulations for the extinction and absorption coefficients in terms of the size distribution parameters predicted from the micro-physical model. The optical depth and single scatter albedo of a cirrus cloud can then be determined, which, along with the asymmetry parameter, are the input parameters needed by cloud radiation models. Through the use of anomalous diffraction theory, analytical expressions were developed describing the absorption and extinction coefficients and the single scatter albedo as functions of size distribution parameters, ice crystal shapes (or habits), wavelength, and refractive index. The extinction coefficient was formulated in terms of the projected area of the size distribution, while the absorption coefficient was formulated in terms of both the projected area and mass of the size distribution. These properties were formulated as explicit functions of ice crystal geometry and were not based on an 'effective radius.' Based on simulations of the second cirrus case study described in Part 1, absorption coefficients predicted in the near infrared for hexagonal columns and rosettes were up to 47% and 71% lower, respectively, than absorption coefficients predicted by using equivalent area spheres. This resulted in single scatter albedos in the near-infrared that were considerably greater than those predicted by the equivalent area sphere method. Reflectances in this region should therefore be underestimated using the equivalent area sphere approach. Cloud optical depth was found to depend on ice crystal habit. When the simulated cirrus cloud contained only bullet rosettes, the optical depth was 142% greater than when the cloud contained only hexagonal columns. This increase produced a doubling in cloud albedo. In the near-infrared (IR), the single scatter albedo also exhibited a significant dependence on ice crystal habit. More research is needed on the geometrical properties of ice crystals before the influence of ice crystal shape on cirrus radiative properties can be adequately understood. This study provides a way of coupling the radiative properties of absorption, extinction, and single scatter albedo to the microphysical properties of cirrus clouds. The dependence of extinction and absorption on ice crystal shape was not just due to geometrical differences between crystal types, but was also due to the effect these differences had on the evolution of ice particle size spectra. The ice particle growth model in Part 1 and the radiative properties treated here are based on analytical formulations, and thus represent a computationally efficient means of modeling the microphysical and radiative properties of cirrus clouds.

Mitchell, David L.↗

NASA NTRS2016

The Microwave Radiative Properties of Falling Snow Derived from Nonspherical Ice Particle Models. Part II: Initial Testing Using Radar, Radiometer and In Situ Observations

In this study, two different particle models describing the structure and electromagnetic properties of snow are developed and evaluated for potential use in satellite combined radar-radiometer precipitation estimation algorithms. In the first model, snow particles are assumed to be homogeneous ice-air spheres with single-scattering properties derived from Mie theory. In the second model, snow particles are created by simulating the self-collection of pristine ice crystals into aggregate particles of different sizes, using different numbers and habits of the collected component crystals. Single-scattering properties of the resulting nonspherical snow particles are determined using the discrete dipole approximation. The size-distribution-integrated scattering properties of the spherical and nonspherical snow particles are incorporated into a dual-wavelength radar profiling algorithm that is applied to 14- and 34-GHz observations of stratiform precipitation from the ER-2 aircraft-borne High-Altitude Imaging Wind and Rain Airborne Profiler (HIWRAP) radar. The retrieved ice precipitation profiles are then input to a forward radiative transfer calculation in an attempt to simulate coincident radiance observations from the Conical Scanning Millimeter-Wave Imaging Radiometer (CoSMIR). Much greater consistency between the simulated and observed CoSMIR radiances is obtained using estimated profiles that are based upon the nonspherical crystal/aggregate snow particle model. Despite this greater consistency, there remain some discrepancies between the higher moments of the HIWRAP-retrieved precipitation size distributions and in situ distributions derived from microphysics probe observations obtained from Citation aircraft underflights of the ER-2. These discrepancies can only be eliminated if a subset of lower-density crystal/aggregate snow particles is assumed in the radar algorithm and in the interpretation of the in situ data.

Ice particles; Radiances; Radiative transfer; Airc↗

NASA NTRS1989

Cirrus optical depth retrieval from satellite-measured bidirectional reflectance

In the framework of investigating the relationship between the visible optical depth and microphysics of cirrus clouds, the doubling scheme for radiative transfer in cirrus cloudy atmospheres, as developed by Takano and Liou (1988), has been used to compute the bidirectional reflectances at the top of the atmosphere. Reflectance data taken at about the same time from GOES and AVHRR over Waussau, as well as particle distributions observed during the FIRE IFO carried out in Wisconsin (1986) were the basis of the experiment. For the cirrus microphysical model, hexagonal ice crystals and area-equivalent ice spheres are considered. The single scattering phase functions for randomly oriented hexagonal columns and area-equivalent ice spheres are computed from geometric optics and Mie theory, respectively.

Takano, Y.↗

NASA NTRS1990

Morphological stability and kinetics in crystal growth from vapors

The following topics are discussed: (1) microscopy image storage and processing system; (2) growth kinetics and morphology study with carbon tetrabromide; (3) photothermal deflection vapor growth setup; (4) bridgman growth of iodine single crystals; (5) vapor concentration distribution measurement during growth; and (6) Monte Carlo modeling of anisotropic growth kinetics and morphology. A collection of presentations and publications of these results are presented.

Rosenberger, Franz↗

NASA NTRS2000

Design, Fabrication and Test of a High Efficiency Refractive Secondary Concentrator for Solar Applications

Common to many of the space applications that utilize solar thermal energy such as electric power conversion, thermal propulsion, and furnaces, is a need for highly efficient, solar concentration systems. An effort is underway to develop the refractive secondary concentrator, which uses refraction and total internal reflection to efficiently concentrate and direct solar energy. When used in combination with advanced primary concentrators, the refractive secondary concentrator enables very high system concentration ratios (10,000 to 1) and very high temperatures (greater than 2000 K). Presented is an overview of the effort at the NASA Glenn Research Center to evaluate the performance of a prototype single crystal sapphire refractive secondary concentrator and to compare the performance with analytical models. The effort involves the design and fabrication of a secondary concentrator, design and fabrication of a calorimeter and its support hardware, calibration of the calorimeter, testing of the secondary concentrator in NASA Glenn's Tank 6 solar thermal vacuum facility, and comparing the test results with predictions. Test results indicate an average throughput efficiency of 87%. It is anticipated that reduction of a known reflection loss with an anti-reflective coating would result in a secondary concentrator throughput efficiency of approximately 93%.

Wong, Wayne A.↗