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Quarterly report describes progress in three programs: dc sputtering machine for aluminum and aluminum alloys; two dimensional computer modeling of MOS transistors; and development of computer techniques for calculating redistribution diffusion of dopants in silicon on sapphire films.
Work performed on several existing solidification models for which computer codes and documentation were developed is presented. The models describe the solidification of alloys in which there is a time varying zone of coexisting solid and liquid phases; i.e., the S/L zone. The primary purpose of the models is to calculate macrosegregation in a casting or ingot which results from flow of interdendritic liquid in this S/L zone during solidification. The flow, driven by solidification contractions and by gravity acting on density gradients in the interdendritic liquid, is modeled as flow through a porous medium. In Model 1, the steady state model, the heat flow characteristics are those of steady state solidification; i.e., the S/L zone is of constant width and it moves at a constant velocity relative to the mold. In Model 2, the unsteady state model, the width and rate of movement of the S/L zone are allowed to vary with time as it moves through the ingot. Each of these models exists in two versions. Models 1 and 2 are applicable to binary alloys; models 1M and 2M are applicable to multicomponent alloys.
A method has been developed for the determination of trapped hydrogen in metal alloys, involving the determination of mobile hydrogen using the electrochemical method and the determination of total hydrogen with the fusion method, the difference in hydrogen concentrations being due to trapped hydrogen. It has been found that hydrogen enters body-centered cubic structures through the grain bodies rather than through the grain boundaries. Hydrogen also diffuses much more rapidly in body-centered cubic structures on charging than in face-centered cubic structures, the hydrogen distribution being more uniform in nature. The energy necessary to cause hydrogen embrittlement is postulated to arise from the changes in crystal lattice energies brought about through interaction of hydrogen with atoms in the metal lattice. The total energy change is more negative for body-centered cubic structures, believed to be the cause of a greater tendency toward hydrogen embrittlement. Finally, the agreement of hydrogen concentrations obtained at 25 C by the electrochemical method with those obtained by the fusion method are taken as a strong indication of the power and validity of the electrochemical method.
An oscillating-cup viscometer was developed to measure viscosity of molten HgZnTe ternary semiconductor alloys. Data were collected for the pseudobinary Hg(0.84)Zn(0.16)Te melt between 770 and 850 C. The kinematic viscosity was found to vary from approximately 1.1 to 1.4 x 10(sup -3)sq cm/s. A slow relaxation phenomena was also observed for temperatures from the melting point of 770 to approx. 800 C. Possible mechanisms for this effect are discussed.
Interior noise and sonic fatigue are important issues in the development and design of advanced subsonic and supersonic aircraft. Conventional aircraft typically employ passive treatments, such as constrained layer damping and acoustic absorption materials, to reduce the structural response and resulting acoustic levels in the aircraft interior. These techniques require significant addition of mass and only attenuate relatively high frequency noise transmitted through the fuselage. Although structural acoustic coupling is in general very important in the study of aircraft fuselage interior noise, analysis of noise transmission through a panel supported in an infinite rigid baffle (separating two semi-infinite acoustic domains) can be useful in evaluating the effects of active/adaptive materials, complex loading, etc. Recent work has been aimed at developing adaptive and/or active methods of controlling the structural acoustic response of panels to reduce the transmitted noise1. A finite element formulation was recently developed to study the dynamic response of shape memory alloy (SMA) hybrid composite panels (conventional composite panel with embedded SMA fibers) subject to combined acoustic and thermal loads2. Further analysis has been performed to predict the far-field acoustic radiation using the finite element dynamic panel response prediction3. The purpose of the present work is to validate the panel vibration and acoustic radiation prediction methods with baseline experimental results obtained from an isotropic panel, without the effect of SMA.
The power density of a gearbox is an important consideration for many applications and is especially important for gearboxes used on aircraft. One approach to improving power density of gearing is to improve the steel properties by design of the alloy. The alloy tested in this work was designed to be case-carburized with surface hardness of Rockwell C66 after hardening. Test gear performance was evaluated using surface fatigue tests and single-tooth bending fatigue tests. The performance of gears made from the new alloy was compared to the performance of gears made from two alloys currently used for aviation gearing. The new alloy exhibited significantly better performance in surface fatigue testing, demonstrating the value of the improved properties in the case layer. However, the alloy exhibited lesser performance in single-tooth bending fatigue testing. The fracture toughness of the tested gears was insufficient for use in aircraft applications as judged by the behavior exhibited during the single tooth bending tests. This study quantified the performance of the new alloy and has provided guidance for the design and development of next generation gear steels.
In support of the GPS for the SAM instrument suite built by NASA/GSFC, a life test facility was developed to test the suitability of 80Ni-20Cr alloy wire, 0.0142 cm diameter, for use as a heater element for the carbon dioxide scrubber. The element would be required to operate at 1000 C in order to attain the 800 C required for regeneration of the getter. The element also would need to operate in the Mars atmosphere, which consists mostly of CO2 at pressures between 4 and 12 torr. Data on the high temperature degradation mechanism of 80Ni- 20Cr in low pressure CO2, coupled with the effects of thermal cycling, were unknown. In addition, the influence of work hardening of the wire during assembly and the potential for catastrophic grain growth also were unknown. Verification of the element reliability as defined by the mission goals required the construction of a test facility that would accurately simulate the duty cycles in a simulated Mars atmosphere. The experimental set-up, along with the test protocol and results will be described.
Systems for identifying objects by means of x-ray fluorescence (XRF) of encased labeling elements have been developed. The XRF spectra of objects so labeled would be analogous to the external bar code labels now used to track objects in everyday commerce. In conjunction with computer-based tracking systems, databases, and labeling conventions, the XRF labels could be used in essentially the same manner as that of bar codes to track inventories and to record and process commercial transactions. In addition, as summarized briefly below, embedded XRF labels could be used to verify the authenticity of products, thereby helping to deter counterfeiting and fraud. A system, as described above, is called an encased core product identification and authentication system (ECPIAS). The ECPIAS concept is a modified version of that of a related recently initiated commercial development of handheld XRF spectral scanners that would identify alloys or detect labeling elements deposited on the surfaces of objects. In contrast, an ECPIAS would utilize labeling elements encased within the objects of interest. The basic ECPIAS concept is best illustrated by means of an example of one of several potential applications: labeling of cultured pearls by labeling the seed particles implanted in oysters to grow the pearls. Each pearl farmer would be assigned a unique mixture of labeling elements that could be distinguished from the corresponding mixtures of other farmers. The mixture would be either incorporated into or applied to the surfaces of the seed prior to implantation in the oyster. If necessary, the labeled seed would be further coated to make it nontoxic to the oyster. After implantation, the growth of layers of mother of pearl on the seed would encase the XRF labels, making these labels integral, permanent parts of the pearls that could not be removed without destroying the pearls themselves. The XRF labels would be read by use of XRF scanners, the spectral data outputs of which would be converted to alphanumeric data in a digital equivalent data system (DEDS), which is the subject of the previous article. These alphanumeric data would be used to track the pearls through all stages of commerce, from the farmer to the retail customer.
The results of compression tests on 44 stiffened plywood panels are presented and correlated in groups for the three types of failure observed: column failure, failure by separation of plywood from stiffener, and crushing failure. The expanded program of military aircraft construction has made it necessary to seek substitute materials that can be used in aircraft in place of aluminum alloys. Wood is one of these substitute materials. The development of synthetic resins as bonding and impregnating agents has resulted in the production of plywood which is being used in stressed-skin structures for aircraft. The use of plywood in such structures necessitates that tests be performed. to determine allowable stress values for use in design, This report presents a preliminary analysis of the results of compression tests on 44 stiffened plywood panels made by the Universal Moulded Products Corporation. The tests were made in a testing machine of 1,200,000 pounds capacity in the NACA structures research laboratory.
Nickel-titanium (NiTi) alloys are an emerging class of materials for rolling element bearing applications that require superior corrosion resistance and/or high load capability. Certain space mechanisms fall into one or both of those categories. Often, due to size and mass considerations, space mechanism systems are limited in torque margin and necessarily require small, precision-instrument bearings with very little frictional drag (i.e., low torque). In addition, space mechanism bearings must survive launch conditions without suffering raceway dents known as brinnelling, which would increase operating torque and reduce overall smoothness. Consequently, a bearing material or design that reduces or eliminates brinnelling under high contact stress conditions would represent a beneficial technology advancement. One specific alloy, nickel-titanium-hafnium (NiTi-Hf), under development for several years at the NASA Glenn Research Center as a bearing material, has the potential to mitigate concerns about brinnelling under extreme load conditions due to its unusually high elastic strain capability. In the present work, a sample of small precision bearings produced with three different ball materials (steel, ceramic, and NiTi-Hf) is subjected to a range of load conditions sufficient to dent the races. The dent depth as a function of load is compared and demonstrates that NiTi-Hf has the potential to increase bearing load capacity from the perspective of brinnelling under severe load conditions; additional testing of full NiTi-Hf bearings demonstrates corrosion resistance superior to that of 440C bearings.
The automotive Stirling engine, presently being developed by the U.S. Department of Energy and NASA, uses high-pressure hydrogen as a working fluid; its long-term effects on the properties of alloys are relatively unknown. Hence, creep-rupture testing of wrought and cast high-temperature alloys in high-pressure hydrogen is an essential part of the research supporting the development of the Stirling cycle engine. Attention is given to the design, development, and operation of a 20 MPa hydrogen high-temperature multispecimen creep-rupture possessing high sensitivity. This pressure vessel allows for the simultaneous yet independent testing of six specimens. The results from one alloy, XF-818, are presented to illustrate how reported results are derived from the raw test data.
Materials and cooling of aircraft gas turbine engines, noting nickel and tantalum alloys, turbine-inlet temperatures, coatings, etc
Materials and cooling of aircraft gas turbine engines noting nickel and tantalum alloys, turbine inlet temperatures, coatings, etc
Interrelated research and development activities, phased development of stepped specimen program are documented and a sequence for a specific program of machining, validation and heat treatment cycles for one material are described. Proposed work for the next phase of dimensional stability research is presented and further technology development activities are proposed.
The NASA Glenn Research Center is developing smart adaptive structures to improve fan blade damping at resonances using piezoelectric (PE) transducers. In this paper, a digital resonant control technique emulating passive shunt circuits is used to demonstrate vibration reduction of FAN1 Ti real fan blade at the several target modes. Single-mode control and multi-mode control using one piezoelectric material are demonstrated. Also a conceptual study of how to implement this digital control system into the rotating fan blade is discussed.
The objective is to characterize the fracture behavior and to define the fracture mechanisms for new Al-Li-Cu alloys, with emphasis on the role of indium additions and cryogenic temperatures. Three alloys were investigated in rolled product form: 2090 baseline and 2090 + indium produced by Reynolds Metals, and commercial AA 2090-T81 produced by Alcoa. The experimental 2090 + In alloy exhibited increases in hardness and ultimate strength, but no change in tensile yield strength, compared to the baseline 2090 composition in the unstretched T6 condition. The reason for this behavior is not understood. Based on hardness and preliminary Kahn Tear fracture experiments, a nominally peak-aged condition was employed for detailed fracture studies. Crack initiation and growth fracture toughness were examined as a function of stress state and microstructure using J(delta a) methods applied to precracked compact tension specimens in the LT orientation. To date, J(delta a) experiments have been limited to 23 C. Alcoa 2090-T81 exhibited the highest toughness regardless of stress state. Fracture was accompanied by extensive delamination associated with high angle grain boundaries normal to the fatigue precrack surface and progressed microscopically by a transgranular shear mechanism. In contrast the two peak-aged Reynolds alloys had lower toughness and fracture was intersubgranular without substantial delamination. The influences of cryogenic temperature, microstructure, boundary precipitate structure, and deformation mode in governing the competing fracture mechanisms will be determined in future experiments. Results contribute to the development of predictive micromechanical models for fracture modes in Al-Li alloys, and to fracture resistant materials.
The results are presented of a program designed to develop life prediction and constitutive models for two coated single crystal alloys used in gas turbine airfoils. The two alloys are PWA 1480 and Alloy 185. The two oxidation resistant coatings are PWA 273, an aluminide coating, and PWA 286, an overlay NiCoCrAlY coating. To obtain constitutive and fatigue data, tests were conducted on uncoated and coated specimens loaded in the CH76 100 CH110 , CH76 110 CH110 , CH76 111 CH110 and CH76 123 CH110 crystallographic directions. Two constitutive models are being developed and evaluated for the single crystal materials: a micromechanic model based on crystallographic slip systems, and a macroscopic model which employs anisotropic tensors to model inelastic deformation anisotropy. Based on tests conducted on the overlay coating material, constitutive models for coatings also appear feasible and two initial models were selected. A life prediction approach was proposed for coated single crystal materials, including crack initiation either in the coating or in the substrate. The coating initiated failures dominated in the tests at load levels typical of gas turbine operation. Coating life was related to coating stress/strain history which was determined from specimen data using the constitutive models.
An evaluation is made of the development status of materials processing techniques in microgravity environments; the classes of materials treated to date encompass glasses, ceramics, crystals, semiconductors, metals and their alloys, polymers, composites, and such biological substances as pharmaceuticals. Attention is given to the commercial development of composite and mixed-phase materials with substantially improved properties as a result of microgravity processing, as well as to current research into catalysts and Type II-VI semiconductor crystals such as CdTe.