Results for “high strength” — Page 55

DOE OSTI2022

Detecting missing struts in metallic micro-lattices using high speed melt pool thermal monitoring

Metal lattices are an important class of cellular materials that offer great advantages by providing high-strength and lightweight structures as compared to bulk materials. Progress in additive manufacturing techniques has led to increased complexity in design and shape of produced objects and is greatly beneficial for the development of metallic lattice structures. However additive manufacturing of lattices suffers from unpredictable defect creation that can compromise its mechanical integrity. Although post-build inspection techniques can provide quality assurance of the process, accurate assessment can be technically challenging, time consuming and costly. In this work, we investigate the use of high-speed measurements of thermal emission from the melt pool to identify defective individual struts formed with a missing bottom half in an otherwise fully built lattice structure produced with laser powder bed fusion. Surprisingly, results indicate lower photodiode signal, suggesting colder melt pool surface temperature, when printing struts with missing bottom half as compared to nominal struts. Additional thermographic imaging and multi-physics simulations reveal that the low photodiode signal is accompanied by presence of hot spatters carrying heat away from detection and continuous avalanche of powder on the melt pool. Based on these observations, a method was developed to identify defective individual struts with missing bottom half in full built lattices. This prediction approach provides valuable insights about part quality which are important for process qualification and illustrates the utility of melt pool thermal emission monitoring for identifying specific defects introduced by laser powder bed fusion.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Cryogenic piping material selection for the Component Test Facility (CTF)

The anticipated high cost of the 8500 psi cryogenic and 15,000 psi gas piping systems used in the CTF at NASA's John C. Stennis Space Center led to the consideration of high-strength materials for these piping systems. Based on years of satisfactory service using austenitic stainless steels in cryogenic applications, particularly for hydrogen service, consideration was limited to the austenitic stainless steels. Attention was focused on alternatives to the 304/304L grades of stainless steel traditionally used in these applications. This paper discusses the various considerations that resulted in the decision to continue using 304/304L for the cryogenic piping and the selection of the nitrogen-strengthened 21Cr-6Ni-9Mn alloy (UNS S21903) for the high-pressure gas systems at the CTF.

St. Cyr, William W.↗

NASA NTRSDate not supplied

The High Inclination Solar Mission (HISM)

The High Inclination Solar Mission (HISM) is a concept for an out-of-the-ecliptic mission for observing the Sun and the heliosphere. The mission profile is largely based on the Solar Polar Imager concept; initially taking ~2.6 yrs to spiral in to a 0.48 AU equatorial orbit, then increasing the orbital inclination at a rate of 10 degrees per year, ultimately reaching an inclination of >75 degrees at the end of the mission. The orbital profile is achieved using solar sails derived from the technology currently being developed for the Solar Cruiser mission. HISM remote sensing instruments comprise an imaging spectropolarimeter (Doppler imager/magnetograph) and a visible light coronagraph. The in-situ instruments include a Faraday cup, an ion composition spectrometer, and magnetometers. Plasma wave measurements are made with electrical antennas and high speed magnetometers. The 7,000 m2 sail used in mission assessment is a direct extension of the 4-quadrant, 1,600 m2 Solar Cruiser Phase-A design and employs the same type of high strength composite boom, deployment mechanism, and membrane technology. The sail system modeled is spun (~1 rpm) to assure required boom characteristics with margin. The spacecraft bus features a fine-pointing 3-axis stabilized instrument platform that allows full science observations as soon as the spacecraft reaches the 0.48 AU orbit.

Solar sail, high inclination, solar physics, helio↗

DOE OSTI2021

Tailoring Microstructure and Mechanical Properties of Additively-Manufactured Ti6Al4V Using Post Processing

Additively-manufactured Ti-6Al-4V (Ti64) exhibits high strength but in some cases inferior elongation to those of conventionally manufactured materials. Post-processing of additively manufactured Ti64 components is investigated to modify the mechanical properties for specific applications while still utilizing the benefits of the additive manufacturing process. The mechanical properties and fatigue resistance of Ti64 samples made by electron beam melting were tested in the as-built state. Several heat treatments (up to 1000 °C) were performed to study their effect on the microstructure and mechanical properties. Phase content during heating was tested with high reliability by neutron diffraction at Los Alamos National Laboratory. Two different hot isostatic pressings (HIP) cycles were tested, one at low temperature (780 °C), the other is at the standard temperature (920 °C). The results show that lowering the HIP holding temperature retains the fine microstructure (~1% β phase) and the 0.2% proof stress of the as-built samples (1038 MPa), but gives rise to higher elongation (~14%) and better fatigue life. The material subjected to a higher HIP temperature had a coarser microstructure, more residual β phase (~2% difference), displayed slightly lower Vickers hardness (~15 HV10N), 0.2% proof stress (~60 MPa) and ultimate stresses (~40 MPa) than the material HIP’ed at 780 °C, but had superior elongation (~6%) and fatigue resistance. Heat treatment at 1000 °C entirely altered the microstructure (~7% β phase), yield elongation of 13.7% but decrease the 0.2% proof-stress to 927 MPa. The results of the HIP at 780 °C imply it would be beneficial to lower the standard ASTM HIP temperature for Ti6Al4V additively manufactured by electron beam melting.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Post-Flight Quantification of LOFTID Aeroshell Deflection Using Feature Tracking

The Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) was a flight demonstration of the Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology, which has the potential to enable delivery of heavy payloads to Mars, Venus, and Titan, as well as return to Earth. Unlike rigid aeroshells that are constrained by the diameter of the launch vehicle shroud, inflatable aeroshells can be deployed to a much larger drag area, thus allowing a more massive spacecraft to begin its deceleration at higher altitudes and experience less heating. On November 10, 2022, the LOFTID reentry vehicle launched aboard a United Launch Alliance Atlas V rocket to low-Earth orbit. The aeroshell was inflated to its full 6-meter diameter, and the vehicle then successfully re-entered the atmosphere, landing in the Pacific Ocean. The aeroshell was composed of seven tori bound together by high strength straps to create a 70-degree half-angle sphere-cone, and the forebody was covered with a flexible thermal protection system (FTPS) (Fig. 1). The centerbody of the vehicle housed six visual cameras. Each camera was made up of 1920 x 1080 pixels and had a field-of-view (FOV) of 85.4° x 55.6°, resulting in a resolution of less than 0.1" at all locations on the aftbody side of the aeroshell. The approximate locations of the cameras and their associated FOVs is shown in Fig. 2. The high loads experienced during flight resulted in the cone of the aeroshell deflecting. This behavior was seen during the static load testing of the aeroshell in May 2021, in which loads ranging from 1,000 to 20,000 lbf were applied, and deflections of up to ~1.7° were observed. The LOFTID team was interested in estimating the deflection of the aeroshell during the its entry into Earth's atmosphere. Before launch, 1"-diameter black circles were drawn on select structural straps for tracking with the visual cameras; the change in position of these features could then be used to calculate aeroshell deflection angle.

Hannah S. Alpert↗

NASA NTRSDate not supplied

Post-Flight Quantification of LOFTID Aeroshell Deflection Using Feature Tracking

The Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) was a flight demonstration of the Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology, which has the potential to enable delivery of heavy payloads to Mars, Venus, and Titan, as well as return to Earth. Unlike rigid aeroshells that are constrained by the diameter of the launch vehicle shroud, inflatable aeroshells can be deployed to a much larger drag area, thus allowing a more massive spacecraft to begin its deceleration at higher altitudes and experience less heating. On November 10, 2022, the LOFTID reentry vehicle launched aboard a United Launch Alliance Atlas V rocket to low-Earth orbit. The aeroshell was inflated to its full 6-meter diameter, and the vehicle then successfully re-entered the atmosphere, landing in the Pacific Ocean. The aeroshell was composed of seven tori bound together by high strength straps to create a 70-degree half-angle sphere-cone, and the forebody was covered with a flexible thermal protection system (FTPS) (Fig. 1). The centerbody of the vehicle housed six visual cameras. Each camera was made up of 1920 x 1080 pixels and had a field-of-view (FOV) of 85.4° x 55.6°, resulting in a resolution of less than 0.1" at all locations on the aftbody side of the aeroshell. The approximate locations of the cameras and their associated FOVs is shown in Fig. 2. The high loads experienced during flight resulted in the cone of the aeroshell deflecting. This behavior was seen during the static load testing of the aeroshell in May 2021, in which loads ranging from 1,000 to 20,000 lbf were applied, and deflections of up to ~1.7° were observed. The LOFTID team was interested in estimating the deflection of the aeroshell during the its entry into Earth's atmosphere. Before launch, 1"-diameter black circles were drawn on select structural straps for tracking with the visual cameras; the change in position of these features could then be used to calculate aeroshell deflection angle.

Hannah S. Alpert↗

DOE OSTI2023

Multimodal and multiscale strengthening mechanisms in Al-Ni-Zr-Ti-Mn alloy processed by laser powder bed fusion additive manufacturing

The unique thermokinetics of laser-powder bed fusion additive manufacturing (L-PBFAM) has been exploited for development of a novel high-strength Al-Ni-Ti-Zr-Mn alloy. The addition of 0.5 wt% Mn leads to extraordinary improvement in ultimate tensile strength (502 MPa) and work hardening due to the activation of two Mn-induced strengthening mechanisms. First, by a bimodal particle strengthening effect due to Al 31 Mn 6 Ni 12 nano-quasi-crystal particles rejected in inter-dendritic spaces and fibrous Al 3 Ni eutectic dendritic channels, which predominately contributes to the strength improvement, and second by solid solution strengthening from remaining Mn entrapped in Al. These mechanisms supplement the particle strengthening effect imparted by coherent and incoherent Al 3 (Ti,Zr) co-precipitates present at melt pool boundaries, dislocation strengthening due to solidification induced strain, and Hall-Petch and backstress strengthening effect due to heterogenous grain size distribution occurring at various length scales. In conclusion, the solidification dynamics and hierarchical heat distribution that are associated with L-PBFAM resulted in complex spatial variations in these strengthening phenomena and were investigated via a high-throughput multiscale structure–property correlation that involved thermokinetic simulation, X-ray diffraction, high-resolution nanoindentation mapping, and site-specific transmission electron microscopy of the alloy.

36 MATERIALS SCIENCE↗

DOE OSTI2020

High-throughput additive manufacturing and characterization of refractory high entropy alloys

Refractory High Entropy Alloys (RHEAs) and Refractory Complex Concentrated Alloys (RCCAs) are high-temperature structural alloys ideally suited for use in harsh environments. While these alloys have shown promising structural properties at high temperatures that exceed the practical limits of conventional alloys, such as Ni-based superalloys, exploration of the complex phase-space of these materials remains a significant challenge. We report on a high-throughput alloy processing and characterization methodology, leveraging laser-based metal additive manufacturing (AM) and mechanical testing techniques, to enable rapid exploration of RHEAs/RCCAs. We utilized in situ alloying and compositional grading, unique to AM processing, to rapidly-produce RHEAs/RCCAs using readily available and inexpensive commercial elemental powders. We demonstrate this approach with the MoNbTaW alloy system, as a model material known for having exceptionally high strength at elevated temperature when processed using conventional methods (e.g., casting). Microstructure analysis, chemical composition, and strain rate dependent hardness of AM-processed material are presented and discussed in the context of understanding the structure-properties relationships of RHEAs/RCCAs.

36 MATERIALS SCIENCE↗

NASA NTRS2007

Free-to-Roll Testing of Airplane Models in Wind Tunnels

A free-to-roll (FTR) test technique and test rig make it possible to evaluate both the transonic performance and the wingdrop/ rock behavior of a high-strength airplane model in a single wind-tunnel entry. The free-to-roll test technique is a single degree-of-motion method in which the model is free to roll about the longitudinal axis. The rolling motion is observed, recorded, and analyzed to gain insight into wing-drop/rock behavior. Wing-drop/rock is one of several phenomena symptomatic of abrupt wing stall. FTR testing was developed as part of the NASA/Navy Abrupt Wing Stall Program, which was established for the purposes of understanding and preventing significant unexpected and uncommanded (thus, highly undesirable) lateral-directional motions associated with wing-drop/rock, which have been observed mostly in fighter airplanes under high-subsonic and transonic maneuvering conditions. Before FTR testing became available, wingrock/ drop behavior of high-performance airplanes undergoing development was not recognized until flight testing. FTR testing is a reliable means of detecting, and evaluating design modifications for reducing or preventing, very complex abrupt wing stall phenomena in a ground facility prior to flight testing. The FTR test rig was designed to replace an older sting attachment butt, such that a model with its force balance and support sting could freely rotate about the longitudinal axis. The rig (see figure) includes a rotary head supported in a stationary head with a forward spherical roller bearing and an aft needle bearing. Rotation is amplified by a set of gears and measured by a shaft-angle resolver; the roll angle can be resolved to within 0.067 degrees at a rotational speed up to 1,000 degrees/s. An assembly of electrically actuated brakes between the rotary and stationary heads can be used to hold the model against a rolling torque at a commanded roll angle. When static testing is required, a locking bar is used to fix the rotating head rigidly to the stationary head. Switching between the static and FTR test modes takes only about 30 minutes. The FTR test rig was originally mounted in a 16-ft (approximately 4.0-m) transonic wind tunnel, but could just as well be adapted to use in any large wind tunnel. In one series of tests on the FTR rig, static and dynamic characteristics of models of four different fighter airplanes were measured. Two of the models exhibited uncommanded lateral motions; the other two did not. A figure of merit was developed to discern the severity of lateral motions. Using this figure of merit, it was shown that the FTR test technique enabled identification of conditions under which the uncommanded lateral motions occurred. The wind-tunnel conditions thus identified were found to be correlated with flight conditions under which the corresponding full-size airplanes exhibited uncommanded lateral motions.

Capone, Francis J.↗

DOE OSTI2021

Solid-state rigid-rod polymer composite electrolytes with nanocrystalline lithium ion pathways

A critical challenge for next-generation lithium-based batteries lies in development of electrolytes that enable thermal safety along with use of high-energy-density electrodes. We describe molecular ionic composite (MIC) electrolytes based on an aligned liquid crystalline polymer combined with ionic liquids and concentrated Li salt. This high strength (200 MPa) and non-flammable solid electrolyte possesses outstanding Li + conductivity (1 mS cm -1 at 25 °C) and electrochemical stability (5.6 V vs Li|Li + ) while suppressing dendrite growth and exhibiting low interfacial resistance (32 Ω cm 2 ) and overpotentials (≤ 120 mV @ 1 mA cm -2 ) during Li symmetric cell cycling. A heterogeneous salt doping process modifies a locally ordered polymer-ion assembly to incorporate an inter-grain network filled with defective LiFSI & LiBF 4 nanocrystals, strongly enhancing Li + conduction. Furthermore, this modular material fabrication platform shows promise for safe and high-energy-density energy storage and conversion applications, incorporating the fast transport of ceramic-like conductors with the superior flexibility of polymer electrolytes.

25 ENERGY STORAGE↗

DOE OSTI2022

Cold Spray Additive Manufacturing For New Pipeline Fabrication In Live, Natural Gas Distribution Mains

ULC Technologies (ULC) and the Penn State University Applied Research Lab (PSU ARL) developed a process and approach for rehabilitating live, natural gas distribution pipelines using Cold Spray Additive Manufacturing (CSAM). Robotic inline fabrication of a new pipe will be performed inside a natural gas main without disrupting customers. The material studied was blended with stainless steel which offers corrosion resistance, high strength and compatibility with hydrogen to enable a robust pipeline system that is future proofed. Stainless steel coatings sprayed and tested in the lab showed excellent strength, ductility, and porosity values. ULC initially sought to use methane as the process gas for compatibility with the host pipe, but after evaluating the field and lab challenges, nitrogen was deemed to be more suitable. Early robotic concepts have been developed that indicate technical feasibility. While the technology development originally targeted natural gas distribution mains, market research showed a broader need. Spot repairs performed in natural gas transmission mains may be a more economical approach for reinforcing distribution and transmission mains compared with full pipe-in-pipe rehabilitation. Additive manufacturing offers custom programming, as well as high accuracy and precision. This means custom contours can be manufactured in situ, offering flexibility in the repair solution, such as fabricating internal full circumferential sleeves. The value of the repair can be high at difficult-to-reach locations and in pipes that need reinforcement before the injection of methane-hydrogen blends.

03 NATURAL GAS↗

NASA NTRS1993

Ceramic silicon-boron-carbon fibers from organic silicon-boron-polymers

Novel high strength ceramic fibers derived from boron, silicon, and carbon organic precursor polymers are discussed. The ceramic fibers are thermally stable up to and beyond 1200 C in air. The method of preparation of the boron-silicon-carbon fibers from a low oxygen content organosilicon boron precursor polymer of the general formula Si(R2)BR(sup 1) includes melt-spinning, crosslinking, and pyrolysis. Specifically, the crosslinked (or cured) precursor organic polymer fibers do not melt or deform during pyrolysis to form the silicon-boron-carbon ceramic fiber. These novel silicon-boron-carbon ceramic fibers are useful in high temperature applications because they retain tensile and other properties up to 1200 C, from 1200 to 1300 C, and in some cases higher than 1300 C.

Riccitiello, Salvatore R.↗

NASA NTRS1991

Method of making contamination-free ceramic bodies

Ceramic structures having high strength at temperatures above 1000 C after sintering are made by mixing ceramic powders with binder deflocculants such as guanidine salts of polymeric acids, guanidine salts of aliphatic organic carboxylic acids or guanidine alkylsulfates with the foregoing guanidine salts. The novelty of the invention appears to lie in the substitution of guanidine salts for the alkalai metal salt components or organic fatty acids of the prior art binder-deflocculant, ceramic processing aids whereby no undesirable metal contaminants are present in the final ceramic structure. Guanidine alkylsulfates also replace the Na or K alkylsulfates commonly used with binder-deflocculants in making high temperature ceramic structures.

Philipp, Warren H.↗

DOE OSTI2022

Near‐Room‐Temperature Magnetoelectric Coupling via Spin Crossover in an Iron(II) Complex

Abstract Magnetoelectric coupling is achieved near room temperature in a spin crossover Fe II molecule‐based compound, [Fe(1bpp) 2 ](BF 4 ) 2 . Large atomic displacements resulting from Jahn–Teller distortions induce a change in the molecule dipole moment when switching between high‐spin and low‐spin states leading to a step‐wise change in the electric polarization and dielectric constant. For temperatures in the region of bistability, the changes in magnetic and electrical properties are induced with a remarkably low magnetic field of 3 T. This result represents a successful expansion of magnetoelectric spin crossovers towards ambient conditions. Moreover, the observed 0.3–0.4 mC m −2 changes in the H ‐induced electric polarization suggest that the high strength of the coupling obtained via this route is accessible not just at cryogenic temperatures but also near room temperature, a feature that is especially appealing in the light of practical applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Role of geometric dynamic recrystallization in nanocrystalline alloys

Nanocrystalline and near-nano-grained metals are plagued with an overall lack of ductility and formability. This is in part due to their inability to support the dislocation mechanisms or undergo the same types of transformations that conventional coarse-grained metals access in order to increase their workability. Therefore, despite their advanced properties such as high strength, the manufacturing of such fine-grained metals, which exposes them to multi-axial states of stress in operations such as rolling, drawing, extrusion, forging, and bending, has not been possible. In this work, we address this limitation and highlight an important aspect of geometric dynamic recrystallization (GDRX) in nanocrystalline materials as a way to improve manufacturability. In particular, using two different alloy compositions and two different processing techniques, this study points to the fact that if nanocrystalline or near nano metals can be truly stabilized, they can repeatedly undergo the same types of processes that conventional coarse-grained metals endure, increasing both their formability and hence manufacturability. The results reveal that due to a large number of initial high-angle grain boundaries and large applied compressive strains, GDRX is activated in the absence of any discontinuous dynamic recrystallization (DDRX) or continuous dynamic recrystallization (CDRX). This is a unique aspect of stabilized nanocrystalline materials, as traditionally fine-grained metals are not microstructurally stable enough to accommodate such an event.

36 MATERIALS SCIENCE↗

NASA NTRS1992

A generic model for creep rupture lifetime estimation on fibrous ceramic composites

Because of their high strength and toughness at elevated temperatures, fiber reinforced ceramic composites such as SiC(f)/SiC and SiC(f)/Si3N4 have become candidates for next-generation turbine engine materials. A generic model is proposed for assessing the lifetime of this class of materials when subjected to long-term creep rupture conditions. This 2D model consists of interfacial cracks growing between square grains and rectangular fibers in the direction normal to the principal tensile stress axis. Neglecting transient effects, the total lifetime is derived based on the criterion that rupture is due to coalescence of adjacent cracks. Lifetime is inversely proportional to crack growth rate, volume fraction, and aspect ratio of the fibers; but extremely sensitive to the applied stress, due to the high power of the V-K(I) law. This lifetime estimation seems to be in fair agreement with the creep rupture data of SiC(w)/Si3N4 composite with 0 and 30 vol percent reinforcement tested at 1250 C in air. TEM performed on the postcrept specimens revealed that creep damage is predominantly in the form of microcracks at matrix/matrix as well as fiber/matrix interfaces, approximately in accord with the model simulation.

Chuang, Tze-Jer↗

NASA NTRS2015

X-Ray Optics at NASA Marshall Space Flight Center

NASA's Marshall Space Flight Center (MSFC) engages in research, development, design, fabrication, coating, assembly, and testing of grazing-incidence optics (primarily) for x-ray telescope systems. Over the past two decades, MSFC has refined processes for electroformed-nickel replication of grazing-incidence optics, in order to produce high-strength, thin-walled, full-cylinder x-ray mirrors. In recent years, MSFC has used this technology to fabricate numerous x-ray mirror assemblies for several flight (balloon, rocket, and satellite) programs. Additionally, MSFC has demonstrated the suitability of this technology for ground-based laboratory applications-namely, x-ray microscopes and cold-neutron microscopes and concentrators. This mature technology enables the production, at moderately low cost, of reasonably lightweight x-ray telescopes with good (15-30 arcsecond) angular resolution. However, achieving arcsecond imaging for a lightweight x-ray telescope likely requires development of other technologies. Accordingly, MSFC is conducting a multi-faceted research program toward enabling cost-effective production of lightweight high-resolution x-ray mirror assemblies. Relevant research topics currently under investigation include differential deposition for post-fabrication figure correction, in-situ monitoring and control of coating stress, and direct fabrication of thin-walled full-cylinder grazing-incidence mirrors.

X-ray Optics↗

NASA NTRS2015

X-Ray Optics at NASA Marshall Space Flight Center

NASA's Marshall Space Flight Center (MSFC) engages in research, development, design, fabrication, coating, assembly, and testing of grazing-incidence optics (primarily) for x-ray telescope systems. Over the past two decades, MSFC has refined processes for electroformed-nickel replication of grazing-incidence optics, in order to produce high-strength, thin-walled, full-cylinder x-ray mirrors. In recent years, MSFC has used this technology to fabricate numerous x-ray mirror assemblies for several flight (balloon, rocket, and satellite) programs. Additionally, MSFC has demonstrated the suitability of this technology for ground-based laboratory applications-namely, x-ray microscopes and cold-neutron microscopes and concentrators. This mature technology enables the production, at moderately low cost, of reasonably lightweight x-ray telescopes with good (15-30 arcsecond) angular resolution. However, achieving arcsecond imaging for a lightweight x-ray telescope likely requires development of other technologies. Accordingly, MSFC is conducting a multi-faceted research program toward enabling cost-effective production of lightweight high-resolution x-ray mirror assemblies. Relevant research topics currently under investigation include differential deposition for post-fabrication figure correction, in-situ monitoring and control of coating stress, and direct fabrication of thin-walled full-cylinder grazing-incidence mirrors.

X-ray telescope↗