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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Magnesium Alloys for Space Hardware Design

There have been advances in magnesium alloy development that NASA has not taken into consideration for space hardware because of a lack of test data. Magnesium alloys offer excellent weight reduction, specific strength, and deep space radiation mitigation. Traditionally, magnesium has been perceived as having too poor of a flammability resistance and corrosion resistance to be used for flight. Recent developments in magnesium alloying has led to the formation of two alloys, WE43 and Elektron 21, which are self-extinguishing and significantly less flammable because of their composition. Likewise, an anodizing process called Tagnite was formulated to deter any concern with galvanic and saltwater corrosion. The Materials Science Branch at Kennedy Space Center is currently researching these new alloys and treatments to better understand how they behave in the harsh environment of space. Successful completion of the proposed testing should result in a more thorough understanding of modern aerospace materials and processes, and possibly the permission to use magnesium alloys in future NASA designs.

microstructure↗
NASA NTRSDate not supplied

A Machine Learning Approach to Design Shape Memory Alloys for NASA Applications

Shape memory alloys (SMAs) are a unique class of materials with several remarkable properties including shape recovery, superelasticity, etc. Nickel-titanium (NiTi) based alloys are the most widely studied of this class, with compositions including ternary, quaternary, or higher additions being considered. Especially important for many NASA applications is the ability to tune the martensitic phase transition temperature of NiTi alloys by varying the alloy composition and processing conditions. In addition, low hysteresis and an acceptable recoverable transformation strain are required. Over the past several years, a significant database of SMA properties has been assembled by NASA researchers. Such a database is ideal for data science-based approaches. We present results from our machine learning approach for designing new SMAs with target properties within our range of interest. Our developed models are capable of accurately predicting the transition temperature, hysteresis, and transformation strain of SMAs across a wide range of compositions. This approach has the potential to significantly accelerate the discovery and design of new SMA materials.

Shreyas Jaikumar Honrao↗
DOE OSTI2024

Data for "Integrated ab initio modelling of atomic order and magnetic anisotropy for rare-earth-free magnet design: effects of alloying additions in L1 0 FeNi."

We describe an integrated modelling approach to accelerate the search for novel, single-phase, multicomponent materials with high magnetocrystalline anisotropy (MCA). For a given system we predict the nature of atomic ordering, its dependence on the magnetic state, and then proceed to describe the consequent MCA, magnetisation, and magnetic critical temperature (Curie temperature). Crucially, within our modelling framework, the same ab initio description of a material’s electronic structure determines all aspects. We demonstrate this holistic method by studying the effects of alloying additions in FeNi, examining systems with the general stoichiometries Fe 4 Ni 3 X and Fe 3 Ni 4 X, for additives including X = Pt, Pd, Al, and Co. The atomic ordering behaviour predicted on adding these elements, fundamental for determining a material’s MCA, is rich and varied. Equiatomic FeNi has been reported to require ferromagnetic order to establish the tetragonal L1 0 order suited for significant MCA. Our results show that when alloying additions are included in this material, annealing in an applied magnetic field and/or below a material’s Curie temperature may also promote tetragonal order, along with an appreciable effect on the predicted hard magnetic properties.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Microstructural design in low alloy steels

The evolution of microalloyed steels from plain carbon steels is examined with emphasis on grain size control by use of Nb, Ti and V additions and by the application of controlled rolling. The structural changes during controlled rolling are described as well as the influence of alloying elements on these changes, and on the final microstructure. The achievement of high strength and toughness is discussed including the role of inclusions.

Honeycombe, R. W. K.↗
NASA NTRS2002

Designing Gamma TiAl Alloys (K5 Based) for Use at 840 C and Above

The objective of this program was to investigate how carbon additions and Al content variation affects RT tensile properties and creep performance in gamma TiAl alloys. On the basis of the results from the work four alloys were selected within the composition range of Ti-(44.7-47.0) Al-(1.0-1.7)Cr-3.0Nb-0.2W-0.2B-(0.23-0.43)C-(0, 0.2)Si. Through extensive annealing/aging experiments, detailed observations of microstructure evolution, property measurements and analyses, comprehensive understanding was made in the carbide formation process. It was found that creep properties depend on the distribution of carbide particles, which is controlled not only by the aging process but also the amount ratio fo Al and carbon. From the results and analysis, new creep-resistant alloy compositions are suggested for further development.

Kim, Young-Won↗
NASA NTRSDate not supplied

Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides

Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.

computational materials↗
NASA NTRS1984

A study of environmental characterization of conventional and advanced aluminum alloys for selection and design. Phase 1: Literature review

A review of the literature is presented with the objectives of identifying relationships between various accelerated stress corrosion testing techniques, and for determining the combination of test methods best suited to selection and design of high strength aluminum alloys. The following areas are reviewed: status of stress-corrosion test standards, the influence of mechanical and environmental factors on stress corrosion testing, correlation of accelerated test data with in-service experience, and procedures used to avoid stress corrosion problems in service. Promising areas for further work are identified.

Sprowls, D. O.↗
DOE OSTI2024

Laser powder bed fusion of oxide dispersion-strengthened IN718 alloys: A complementary study on microstructure and mechanical properties

In this study, two new grades of oxide dispersion strengthened (ODS) Inconel 718 (IN718) alloys were designed by the thermochemical CALPHAD method and produced by laser powder bed fusion (LPBF) technique. Alloys designated as IN718-YF and IN718-YFH, that consist Y 2 O 3 –FeO and Y 2 O 3 –FeO–Hf, respectively, were fabricated with >99.9 % densification using optimized process parameters. CALPHAD calculations were highly consistent with experimental findings, highlighting the formation of Al-containing Y–Ti–O and Y–Hf–O nano-oxides in both alloy types. Texture analyzes revealed no significant texture development in as-built (AB) or heat-treated (HT) alloys. Heat treatment was applied at 1050 °C for 1 h to enhance nano-oxide density. Further, the nano-oxide number density remained similar in IN718-YF while it decreased in IN718-YFH alloy as a result of carbide formation after the heat treatment. Besides, formation of secondary γ' particles was observed in the IN718-YFH/HT alloy. Even though the yield strengths of IN718-YF and IN718-YFH alloys in both AB and HT conditions were similar, the ductility of IN718-YFH was ~50 % less in almost all conditions compared to the ductility of IN718-YF. This has been shown to be as a result of irregular shaped micron-sized Y-Hf-O oxides, martensite formation in AB condition, increased amount of carbides and existence of secondary γ' particles in HT condition in IN718-YFH. High density of stacking faults (SF) forming at the interface of the nano-oxides have been detected in IN718-YF alloys. Besides dislocation/nanoparticle interactions, SFs which are responsible for the delocalization of the deformation improve the ductility of IN718-YF alloys. Overall, high temperature mechanical tests exhibit that both alloys have higher strength with improved ductility compared to the standard IN718 alloys, indicating the contribution of the nano-oxides.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Design of a Shape Memory Alloy deployment hinge for reflector facets

A design concept for a Shape Memory Alloy (SMA) actuated hinge mechanism for deploying segmented facet-type reflector surfaces on antenna truss structures is presented. The mechanism uses nitinol, a nickel-titanium shape memory alloy, as a displacement-force micro-actuator. An electrical current is used to resistively heat a 'plastically' elongated SMA actuator wire, causing it to contract in response to a thermally-induced phase transformation. The resulting tension creates a moment, imparting rotary motion between two adjacent panels. Mechanical stops are designed into the device to limit its range of motion and to establish positioning accuracy at the termination of deployment. The concept and its operation are discussed in detail, and an analytical dynamic simulation model is presented. The model has been used to perform nondimensionalized parametric design studies.

Anders, W. S.↗
DOE OSTI2025

Overcoming sparse datasets with multi-task learning as applied to high entropy alloys

Abstract The design of novel High Entropy Alloys for use in high-temperature applications is an area of active interest due to their potential to provide exceptional properties compared to conventional alloys. Since the increased popularity of machine learning, an important cog in the design process has been training surrogate models on alloy properties. However, these Single-Task models are trained on individual mechanical properties and do not take advantage of the relatedness between properties. Multi-Task models can capture the interdependencies between tasks, leading to potentially more accurate predictions for all tasks. In this paper, we investigate if Multi-Task models can show improvement over Single-Task models when used for predicting the mechanical properties of these alloys. To ensure fair evaluation between the models, we apply L 0 regularization and skip connections to the models, which allows them to adjust the number of model parameters and depth for optimal performance. We find that the Multi-Task models can leverage task relationships to perform better than Single-Task models, especially for high amounts of missing data in the tasks. Furthermore, adding simple auxiliary targets can boost Multi-Task performance even further despite not being effective as input descriptors to single-task models themselves. We anticipate that the proposed strategies can achieve more accurate predictions and consequently enable better design capabilities for such data-constrained domains without incurring much additional computational cost.

Debnath, Arindam (ORCID:0000000194274499)↗
NASA NTRS1992

Comparison of high temperature, high frequency core loss and dynamic B-H loops of a 2V-49Fe-49Co and a grain oriented 3Si-Fe alloy

The design of power magnetic components such as transformers, inductors, motors, and generators, requires specific knowledge about the magnetic and electrical characteristics of the magnetic materials used in these components. Limited experimental data exists that characterizes the performance of soft magnetic materials for the combined conditions of high temperature and high frequency over a wide flux density range. An experimental investigation of a 2V-49-Fe-49Co (Supermendur) and a grain oriented 3 Si-Fe (Magnesil) alloy was conducted over the temperature range of 23 to 300 C and frequency range of 0.1 to 10 kHz. The effects of temperature, frequency, and maximum flux density on the core loss and dynamic B-H loops for sinusoidal voltage excitation conditions are examined for each of these materials. A comparison of the core loss of these two materials is also made over the temperature and frequency range investigated.

Wieserman, W. R.↗
NASA NTRS1992

Comparison of high temperature, high frequency core loss and dynamic B-H loops of a 2V-49Fe-49Co and a grain oriented 3Si-Fe alloy

The design of power magnetic components such as transformers, inductors, motors, and generators, requires specific knowledge about the magnetic and electrical characteristics of the magnetic materials used in these components. Limited experimental data exists that characterizes the performance of soft magnetic materials for the combined conditions of high temperature and high frequency over a wide flux density range. An experimental investigation of a 2V-49-Fe-49Co (Supermendur) and a grain oriented 3 Si-Fe (Magnesil) alloy was conducted over the temperature range of 23 to 300 C and frequency range of 0.1 to 10 kHz. The effects of temperature, frequency, and maximum flux density on the core loss and dynamic B-H loops for sinusoidal voltage excitation conditions are examined for each of these materials. A comparison of the core loss of these two materials is also made over the temperature and frequency range investigated.

Wieserman, W. R.↗
NASA NTRS1976

Creep resistance

High-temperature structural applications usually require creep resistance because some average stress is maintained for prolonged periods. Alloy and microstructural design guidelines for creep resistance are presented through established knowledge on creep behavior and its functional dependences on alloy microstructure. Important considerations related to creep resistance of alloys as well as those that are harmful to high-temperature properties are examined. Although most of the creep models do not predict observed creep behavior quantitatively, they are sophisticated enough to provide alloy or microstructural design guidelines. It is shown that creep-resistant microstructures are usually in conflict with microstructures that improve such other properties as stress rupture ductility. Greater understanding of the effects of environments on creep and stress rupture behavior of materials is necessary before one can optimally design alloys for applications in different environments.

Tien, J. K.↗
NASA NTRS1984

A study of environmental characterization of conventional and advanced aluminum alloys for selection and design. Phase 2: The breaking load test method

A technique is demonstrated for accelerated stress corrosion testing of high strength aluminum alloys. The method offers better precision and shorter exposure times than traditional pass fail procedures. The approach uses data from tension tests performed on replicate groups of smooth specimens after various lengths of exposure to static stress. The breaking strength measures degradation in the test specimen load carrying ability due to the environmental attack. Analysis of breaking load data by extreme value statistics enables the calculation of survival probabilities and a statistically defined threshold stress applicable to the specific test conditions. A fracture mechanics model is given which quantifies depth of attack in the stress corroded specimen by an effective flaw size calculated from the breaking stress and the material strength and fracture toughness properties. Comparisons are made with experimental results from three tempers of 7075 alloy plate tested by the breaking load method and by traditional tests of statistically loaded smooth tension bars and conventional precracked specimens.

Sprowls, D. O.↗
NASA NTRS1996

High Temperature Analysis of Aluminum-Lithium 2195 Alloy to Aid in the Design of Improved Welding Techniques

Aluminum-lithium alloys have extraordinary properties. The addition of lithium to an aluminum alloy decreases its density, while making large increases in its strength and hardness. The down side is that they are unstable at higher temperatures, and are subsequently difficult to weld or even manufacture. Martin Marietta, though, developed an aluminum-lithium alloy 2195 that was reported to have exceptional properties and good weldability. Thus, it was chosen as the alloy for the space shuttles super light external tank. Unfortunately, welding 2195 has turned out to be much more of a challenge than anticipated. Thus, research has been undergone in order to understand the mechanisms that are causing the welding problems. Gas reactions have been observed to be detrimental to weld strength. Water vapor has often been identified as having a significant role in these reactions. Nitrogen, however, has also been shown to have a direct correlation to porosity. These reactions were suspected as being complex and responsible for the two main problems of welding 2195. One, the initial welds of 2195 are much weaker than the parent metal. Second, each subsequent welding pass increases the size and number of cracks and porosity, yielding significant reductions in strength. Consequently, the objective of this research was to characterize the high-temperature reactions of 2195 in order to understand the mechanisms for crack growth and the formation of porosity in welds. In order to accomplish that goal, an optical hot-stage microscope, HSM, was used to observe those reactions as they occurred. Surface reactions of 2195 were observed in a variety of environments, such as air, vacuum, nitrogen and helium. For comparison, some samples of Al-2219 were also observed. Some of the reacted surfaces were then analyzed on a scanning electron microscope, SEM. Additionally, a gas chromatograph was used to analyze the gaseous products of the high temperature reactions.

Talia, George E.↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗