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At least 1,153 records · Page 64

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NASA NTRS1986

Constitutive modeling for isotropic materials (HOST)

The results of the third year of work on a program which is part of the NASA Hot Section Technology program (HOST) are presented. The goals of this program are: (1) the development of unified constitutive models for rate dependent isotropic materials; and (2) the demonstration of the use of unified models in structural analyses of hot section components of gas turbine engines. The unified models selected for development and evaluation are those of Bodner-Partom and of Walker. A test procedure was developed for assisting the generation of a data base for the Bodner-Partom model using a relatively small number of specimens. This test procedure involved performing a tensile test at a temperature of interest that involves a succession of strain-rate changes. The results for B1900+Hf indicate that material constants related to hardening and thermal recovery can be obtained on the basis of such a procedure. Strain aging, thermal recovery, and unexpected material variations, however, preluded an accurate determination of the strain-rate sensitivity parameter is this exercise. The effects of casting grain size on the constitutive behavior of B1900+Hf were studied and no particular grain size effect was observed. A systematic procedure was also developed for determining the material constants in the Bodner-Partom model. Both the new test procedure and the method for determining material constants were applied to the alternate material, Mar-M247 . Test data including tensile, creep, cyclic and nonproportional biaxial (tension/torsion) loading were collected. Good correlations were obtained between the Bodner-Partom model and experiments. A literature survey was conducted to assess the effects of thermal history on the constitutive behavior of metals. Thermal history effects are expected to be present at temperature regimes where strain aging and change of microstructure are important. Possible modifications to the Bodner-Partom model to account for these effects are outlined. The use of a unified constitutive model for hot section component analyses was demonstrated by applying the Walker model and the MARC finite-element code to a B1900+Hf airfoil problem.

Chan, Kwai S.↗

NASA NTRS1989

An investigation of some mechanical and thermal properties of lunar simulant materials heated at 2.45 GHz

Lunar simulant material was fabricated to simulate Apollo 11, Apollo 15, and Apollo 16 soils. The approximate compositions which these soils simulate are given. Samples of each soil simulate were fabricated into right circular cylinders, placed into a microwave reaction cavity, and heated using 2.45 GHz radiation to a particular processing temperature at which it was held for a prescribed length of time. Examples are given of two microwave heating programs for these simulant samples. Upon completion of thermal processing, each sample had its top and bottom surfaces polished. A technique was employed which looks at hardness data to determine the fracture toughness of a material and then relates this to thermal shock resistance. Some advantages of this technique are its low cost for analysis and thermal shock resistance as a function of initial sample orientation in the microwave field can be determined. Samples were prepared for testing and results are expected. At the same time, other samples are currently being investigated using scanning electron microscopy to determine their microstructures.

Meek, T. T.↗

NASA NTRS2022

Multiscale Progressive Failure Analysis of 3D Woven Composites

Application of three-dimensional (3D) woven composites is growing as an alternative to the use of ply-based composite materials. However, the design, analysis, modeling, and optimization of these materials is more challenging due to their complex and inherently multiscale geometries. Herein, a multiscale modeling procedure, based on efficient, semi-analytical micromechanical theories rather than the traditional finite element approach, is presented and applied to a 3D woven carbon–epoxy composite. A crack-band progressive damage model was employed for the matrix constituent to capture the globally observed nonlinear response. Realistic microstructural dimensions and tow-fiber volume fractions were determined from detailed X-ray computed tomography (CT) and scanning electron microscopy data. Pre-existing binder-tow disbonds and weft-tow waviness, observed in X-ray CT scans of the composite, were also included in the model. The results were compared with experimental data for the in-plane tensile and shear behavior of the composite. The tensile predictions exhibited good correlations with the test data. While the model was able to capture the less brittle nature of the in-plane shear response, quantitative measures were underpredicted to some degree.

3D woven composites↗

NASA NTRS1983

Relation of cyclic loading pattern to microstructural fracture in creep fatigue

Creep-fatigue-environment interaction is discussed using the 'strainrange partitioning' (SRP) framework as a basis. The four generic SRP strainrange types are studied with a view of revealing differences in micromechanisms of deformation and fatigue degradation. Each combines in a different manner the degradation associated with slip-plane sliding, grain-boundary sliding, migration, cavitation, void development and environmental interaction; hence the approch is useful in delineating the relative importance of these mechanisms in the different loadings. Micromechanistic results are shown for a number of materials, including 316 SS, wrought heat resistant alloys, several nickel-base superalloys, and a tantalum base alloy, T-111. Although there is a commonality of basic behavior, the differences are useful in delineation several important principles of interpretation. Some quantitative results are presented for 316 SS, involving crack initiation and early crack growth, as well as the interaction of low-cycle fatigue with high-cycle fatigue.

Manson, S. S.↗

NASA NTRS1975

The effect of forging history on the strength and microstructure of TDNiCr /Ni-20Cr-2ThO2/

Forging variables were evaluated to determine their influence on the elevated temperature strength and microstructure of TDNiCr. Grain size was the principal microstructural feature related to elevated temperature strength and was controlled primarily by the thermomechanical variables of forging temperature and final annealing condition. Tests at 1366 K revealed a factor of eight increase in tensile strength as grain size increased from 1 to 150 microns, while stress-rupture strength improved by three to five times as grain size increased from 15 to 150 microns. Forged material of grain size greater than or equal to about 150 microns displayed a level of elevated temperature strength comparable to that of optimized TDNiCr sheet. The presence of a preponderance of small twins and a strong preferred orientation may have also been factors contributing to the excellent high temperature strength of large grain forged material.

Filippi, A. M.↗

NASA NTRS1976

Structure-property relationships in eutectic composites

The preparation of a composite material of eutectic composition directly from the molten state is investigated. The manufacture of eutectic composites by unidirectional solidification is reviewed, and it is shown how two-phase composite structures of given relative volume fraction can be produced with a range of particle sizes. Crystallographic relationships and the thermal stability of interfaces in controlled eutectic structures are examined, the mechanical behavior of aligned eutectic microstructures is discussed, and characteristics of eutectic composites having mechanical properties of engineering significance are evaluated. Specific properties of the Ni-Nb eutectic alloy are reviewed to demonstrate the effect of structure control (through directional solidification) on the mechanical response of a eutectic composite. It is noted that unidirectionally solidified eutectic composites possess highly aligned and thermally stable microstructures and also exhibit excellent combinations of strength and ductility to very high temperature levels.

Hertzberg, R. W.↗

NASA NTRS1985

Microstructure and fracture in SiC whisker reinforced 2124 aluminum composite

The microstructures of extruded and hot-rolled 2124 Al-15 percent (by weight) SiC whisker composites have been investigated, experimentally. Among the specific factors studied were: the strength of the whisker-matrix interfaces; (2) the presence of oxides; (3) the presence of defective whiskers; (4) and the presence of distribution of intermetallic compounds, impurities in the SiC(w) powder, and microstructural inhomogeneities. Modifications in the microstructure of the SiC/AL composites due to hot rolling and extrusion are illustrated in a series of microphotographs. It was found that hot rolling along the axis of extrusion was associated with some types of whisker damage, while the whiskers still retain their original orientation. Hot-rolling perpendicular to the axis of extrusion, however, tended to rotate the whiskers and produced a nearly isotropic material. Whisker free zones were virtually eliminated or reduced in size by hot rolling. In situ Auger fractography of the composite showed that the interfacial bonding between the SiC and the Al matrix was good and that Al2O2 had no significant influence on the fracture mechanics of the composite.

Nieh, T. G.↗

NASA NTRS1989

Characterization of ceramics and intermetallics fabricated by self-propagating high-temperature synthesis

Three efforts aimed at investigating the process of self-propagating high temperature synthesis (SHS) for the fabrication of structural ceramics and intermetallics are summarized. Of special interest was the influence of processing variables such as exothermic dopants, gravity, and green state morphology in materials produced by SHS. In the first effort directed toward the fabrication of SiC, exothermic dopants of yttrium and zirconium were added to SiO2 or SiO2 + NiO plus carbon powder mix and processed by SHS. This approach was unsuccessful since it did not produce the desired product of crystalline SiC. In the second effort, the influence of gravity was investigated by examining Ni-Al microstructures which were produced by SHS combustion waves traveling with and opposite the gravity direction. Although final composition and total porosities of the combusted Ni-Al compounds were found to be gravity independent, larger pores were created in those specimens which were combusted opposite to the gravity force direction. Finally, it was found that green microstructure has a significant effect on the appearance of the combusted piece. Severe pressing laminations were observed to arrest the combustion front for TiC samples.

Hurst, Janet B.↗

NASA NTRS1991

Microstructure and mechanical properties of a single crystal NiAl alloy with Zr or Hf rich G-phase precipitates

The possibility of producing NiAl reinforced with the G-phase (Ni16X6Si7), where X is Zr or Hf, has been investigated. The microstructure of these NiAl alloys have been characterized in the as-cast and annealed conditions. The G-phases are present as fine cuboidal precipitates (10 to 40 nm) and have lattice parameters almost four times that of NiAl. They are coherent with the matrix and fairly resistant to coarsening during annealing heat treatments. Segregation and nonuniform precipitate distribution observed in as-cast materials were eliminated by homogenization at temperatures near 1600 K. Slow cooling from these temperatures resulted in large plate shaped precipitates, denuded zones, and a loss of coherency in some of the large particles. Faster cooling produced a homogeneous fine distribution of cuboidal G-phase particles in the matrix. Preliminary mechanical properties for the Zr-doped alloy are presented and compared to binary single crystal NiAl. The presence of these precipitates appears to have an important strengthening effect at temperatures not less than 1000 K compared to binary NiAl single crystals.

Locci, I. E.↗

NASA NTRS2003

Alumina-Reinforced Zirconia Composites

Alumina-reinforced zirconia composites, used as electrolyte materials for solid oxide fuel cells, were fabricated by hot pressing 10 mol percent yttria-stabilized zirconia (10-YSZ) reinforced with two different forms of alumina particulates and platelets each containing 0 to 30 mol percent alumina. Major mechanical and physical properties of both particulate and platelet composites including flexure strength, fracture toughness, slow crack growth, elastic modulus, density, Vickers microhardness, thermal conductivity, and microstructures were determined as a function of alumina content either at 25 C or at both 25 and 1000 C. Flexure strength and fracture toughness at 1000 C were maximized with 30 particulate and 30 mol percent platelet composites, respectively, while resistance to slow crack growth at 1000 C in air was greater for 30 mol percent platelet composite than for 30 mol percent particulate composites.

Choi, Sung R.↗

NASA NTRS1991

Microstructural changes in Beta-silicon nitride grains upon crystallizing the grain-boundary glass

Crystallizing the grain boundary glass of a liquid phase sintered Si3N4 ceramic for 2 h or less at 1500 C led to formation of gamma Y2Si2O7. After 5 h at 1500 C, the gamma Y2Si2O7 had transformed to beta Y2Si2O7 with a concurrent dramatic increase in dislocation density within beta Si3N4 grains. Reasons for the increased dislocation density is discussed. Annealing for 20 h at 1500 C reduced dislocation densities to the levels found in as-sintered materials.

Lee, William E.↗

NASA NTRS1981

The effect of mechanical surface and heat treatments on the erosion resistance of 6061 aluminum alloy

The effects of both mechanical surface treatments and heat treatments on the erosion resistance of 6061 aluminum alloy were studied in order to gain a better understanding of material properties which affect erosion behavior. It was found that mechanical surface treatments have little or no effect on the erosion resistance. This is due to the formation by particle impact of a work-hardened surface layer, independent of the initial surface condition. The erosion resistance of aluminum single crystals was found to be independent of orientation, which is due to destruction of the surface microstructure and formation of a polycrystalline surface layer by the particle impact as observed by X-ray diffraction. Although on solution treatment of annealed aluminum 6061 the increase in hardness is accompanied by an increase in erosion resistance, precipitation treatment (which causes a further increase in hardness) results in a slightly lower erosion resistance.

Salik, J.↗

NASA NTRS2012

ISS-Experiments of Columnar-to-Equiaxed Transition in Solidification Processing

The main topic of the research project CETSOL in the framework of the Microgravity Application Promotion (MAP) programme of the European Space Agency (ESA) is the investigation of the transition from columnar to equiaxed grain growth during solidification. Microgravity environment allows for suppression of buoyancy-driven melt flow and for growth of equiaxed grains free of sedimentation and buoyancy effects. This contribution will present first experimental results obtained in microgravity using hypo-eutectic AlSi alloys in the Materials Science Laboratory (MSL) on-board the International Space Station (ISS). The analysis of the experiments confirms the existence of a columnar to equiaxed transition, especially in the refined alloy. Temperature evolution and grain structure analysis provide critical values for the position, the temperature gradient and the solidification velocity at the columnar to equiaxed transition. These data will be used to improve modeling of solidification microstructures and grain structure on different lengths scales.

Sturz, Laszlo↗

NASA NTRS1992

Monolithic ceramics

A development history and current development status evaluation are presented for SiC and Si3N4 monolithic ceramics. In the absence of widely sought improvements in these materials' toughness, and associated reliability in structural applications, uses will remain restricted to components in noncritical, nonman-rated aerospace applications such as cruise missile and drone gas turbine engine components. In such high temperature engine-section components, projected costs lie below those associated with superalloy-based short-life/expendable engines. Advancements are required in processing technology for the sake of fewer and smaller microstructural flaws.

Herbell, Thomas P.↗

NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗

NASA NTRS1983

Strength and fracture toughness of reaction-bonded Si3N4

Fracture strength and fracture toughness measurements were made on reaction-bonded Si3N4 materials with a range of alpha/beta ratios. The results do not indicate any clear relation between the modulus of rupture and the alpha/beta ratio over the range 1.5-9. Values for the modulus of rupture range from 219 to 290 MN per sq m, with an overall average of 238 MN per sq m. The notched beam fracture toughness is found to be constant over the range of microstructures produced, indicating that of the various microstructural features (e.g., alpha/beta ratio and pore size and distribution) no single element has a controlling influence over fracture toughness and the fracture surface energy.

Danforth, S. C.↗

NASA NTRS1986

Effect of multiple strain-anneal cycles on the 1000 C creep behaviour of gamma/gamma prime-alpha

Various multiple strain-anneal cycles (1000 C) were imposed on specimens of the directionally solidified eutectic (DSE) alloy gamma/gamma prime-alpha to identify thermomechanical processing methods (TMP) which would improve the creep behavior. Specimens of the Ni-32.3Mo-6.3Al wt pct alloy were grown with a modified Bridgeman technique. Some of the cylindrical specimens were alternately heat-treated at 900 C, then strained, or heat-treated only, while other specimens were annealed at 900 C after swaging and then worked at ambient temperature. The specimens were all examined microstructurally using transmission electron microscopy, some before and after being exposed to constant-load compression tests at 1000 C. The creep strain increased for all TMP specimens for strain rates of at least 2 millionths per sec. Strain rates of about 2 ten millionths per sec were only improved with strain annealing with 13 percent work at ambient temperature. A slight improvement, compared to as-grown materials, was observed in the 1000 C creep behavior of materials annealed at 900 C. Strain-annealing was found to introduce three-dimensional dislocation networks into the gamma-prime matrix.

Whittenberger, J. D.↗

NASA NTRS1991

Joining of materials with engineered interlayers

A reliable method to join a variety of different materials is developed which uses engineered coatings to produce strong bonds by solid-state techniques at low temperatures (300-400 C). The strong bonds are capable of accommodating the strains created between Si and most substrates due to differences in thermal expansion coefficients. The approach encompasses two phases: noble metal compliant interlayers and functionally gradient interlayer bonding. Preliminary results are presented and the Ag interlayer bonds are microstructurally characterized confirming that the planar magnetron sputtered coatings/bonds are fully dense and metallurgically sound.

Challenger, Kenneth D.↗