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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Creep Behavior of Compact γ′-γ″ Coprecipitation Strengthened IN718-Variant Superalloy

The development of high-temperature heavy-duty turbine disk materials is critical for improving the overall efficiency of combined cycle power plants. An alloy development strategy to this end involves superalloys strengthened by ‘compact’ γ′-γ″ coprecipitates. Compact morphology of coprecipitates consists of a cuboidal γ′ precipitate such that γ″ discs coat its six {001} faces. The present work is an attempt to investigate the microstructure and creep behavior of a fully aged alloy exhibiting compact coprecipitates. We conducted heat treatments, detailed microstructural characterization, and creep testing at 1200 °F (649 °C) on an IN718-variant alloy. Our results indicate that aged IN718-27 samples exhibit a relatively uniform distribution of compact coprecipitates, irrespective of the cooling rate. However, the alloy ruptured at low strains during creep tests at 1200 °F (649 °C). At 100 ksi (689 MPa) load, the alloy fails around 0.1% strain, and 75 ksi (517 MPa) loading causes rupture at 0.3% strain. We also report extensive intergranular failure in all the tested samples, which is attributed to cracking along grain boundary precipitates. The results suggest that while the compact coprecipitates are indeed thermally stable during thermomechanical processing, the microstructure of the alloy needs to be optimized for better creep strength and rupture life.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.

Holmes, Richard↗
DOE OSTI2022

Low-cost, high-strength, cast creep-resistant alumina-forming alloys for heat-exchangers, supercritical CO2 systems and industrial applications

An austenitic Ni-base alloy includes, in weight percent: 2.5 to 4.75 Al; 13 to 21 Cr; 20 to 40 Fe; 2 to 5 total of at least one element selected from the group consisting of Nb and Ta; 0.25 to 4.5 Ti; 0.09 to 1.5 Si; 0 to 0.5 V; 0 to 2 Mn; 0 to 3 Cu; 0 to 2 of Mo and W; 0 to 1 of Zr and Hf; 0 to 0.15 Y; 0.01 to 0.45 C; 0.005 to 0.1 B; 0 to 0.05 P; less than 0.06 N; and balance Ni (38 to 46 Ni). The weight percent Ni is greater than the weight percent Fe. An external continuous scale comprises alumina. A stable phase FCC austenitic matrix microstructure is essentially delta-ferrite-free, and contains one or more carbides and coherent precipitates of γ′ and exhibits creep rupture life of at least 100 h at 900° C. and 50 MPa.

Muralidharan, Govindarajan↗
NASA NTRS1998

Development and Characterization of SiC)/ MoSi2-Si3N4(p) Hybrid Composites

Intermetallic compound MoSi2 has long been known as a high temperature material that has excellent oxidation resistance and electrical/thermal conductivity. Also its low cost, high melting point (2023 C), relatively low density (6.2 g/cu cm versus 9 g/cu cm for current engine materials), and ease of machining, make it an attractive structural material. However, the use of MoSi2 has been hindered due to its poor toughness at low temperatures, poor creep resistance at high temperatures, and accelerated oxidation (also known as 'pest' oxidation) at temperatures between approximately 450 and 550 C. Continuous fiber reinforcing is very effective means of improving both toughness and strength. Unfortunately, MoSi2 has a relatively high coefficient of thermal expansion (CTE) compared to potential reinforcing fibers such as SiC. The large CTE mismatch between the fiber and the matrix resulted in severe matrix cracking during thermal cycling. Addition of about 30 to 50 vol % of Si3N4 particulate to MoSi2 improved resistance to low temperature accelerated oxidation by forming a Si2ON2 protective scale and thereby eliminating catastrophic 'pest failure'. The Si3N4 addition also improved the high temperature creep strength by nearly five orders of magnitude, doubled the room temperature toughness and significantly lowered the CTE of the MoSi2 and eliminated matrix cracking in SCS-6 reinforced composites even after thermal cycling. The SCS-6 fiber reinforcement improved the room temperature fracture toughness by seven times and impact resistance by five times. The composite exhibited excellent strength and toughness improvement up to 1400 C. More recently, tape casting was adopted as the preferred processing of MoSi2-base composites for improved fiber spacing, ability to use small diameter fibers, and for lower cost. Good strength and toughness values were also obtained with fine diameter Hi-Nicalon tow fibers. This hybrid composite remains competitive with ceramic matrix composites as a replacement for Ni-base superalloys in aircraft engine applications.

Hebsur, Mohan G.↗
DOE OSTI2024

Creep and failure at metal-oxide interfaces

Small-scale bicrystal creep experiments were performed on contacts formed via in situ high-temperature diffusion bonding of metal-oxide interfaces including Ag-ZrO 2 , Pd-ZrO 2 , Pt-ZrO 2 , and Ag-high entropy oxide. This work characterizes deformation and failure at metal-oxide interfaces during mechanical loading. Interfacial sliding can be activated easily, while tensile interfacial creep was not observed at any condition of stress or temperature measured. Plastic strain, instead, localizes within the metal under tensile loading. A variety of mechanisms for plastic strain occur in the metal including lattice dislocation-mediated plasticity, twinning, low-angle grain boundary formation, and low-angle grain boundary creep. Surface and low-angle grain boundary diffusion occur under conditions where no metal-oxide tensile creep is observed, highlighting the significant differences in their interfacial mechanical response. High-temperature interfacial failure occurs when the mean curvature at the contact neck is approximately zero and the applied stresses comparable to brittle fracture stresses. The brittle fracture stresses were measured to be σ ƒ = 180 ± 90 MPa at the Ag-ZrO 2 interface at 225 °C, σ ƒ = 460 ± 160 MPa at the Pd-ZrO 2 interface at 680 °C, and σ ƒ = 640 ± 440 MPa at the Pt-ZrO 2 interface at 1010 °C.

Creep↗
NASA NTRS1999

Robust Low Cost Aerospike/RLV Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. At the same time, fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of a shrinking NASA budget. In recent years, combustion chambers of equivalent size to the Aerospike chamber have been fabricated at NASA-Marshall Space Flight Center (MSFC) using innovative, relatively low-cost, vacuum-plasma-spray (VPS) techniques. Typically, such combustion chambers are made of the copper alloy NARloy-Z. However, current research and development conducted by NASA-Lewis Research Center (LeRC) has identified a Cu-8Cr-4Nb alloy which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. In fact, researchers at NASA-LeRC have demonstrated that powder metallurgy (P/M) Cu-8Cr-4Nb exhibits better mechanical properties at 1,200 F than NARloy-Z does at 1,000 F. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost, VPS process to deposit Cu-8Cr-4Nb with mechanical properties that match or exceed those of P/M Cu-8Cr-4Nb. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the hot wall of the liner during the VPS process. Tensile properties of Cu-8Cr-4Nb material produced by VPS are reviewed and compared to material produced previously by extrusion. VPS formed combustion chamber liners have also been prepared and will be reported on following scheduled hot firing tests at NASA-Lewis.

Holmes, Richard↗
NASA NTRS2020

Controlled Environmental Effects on Creep Test Data of Woven Fabric Webbings for Inflatable Space Modules

eveloping technologies for proposed lunar and Mars space exploration missions. Enhanced habitation sy g studied as potential habitats due to their inherent low mass and small launch volume. One goal of inflatable module research is quantification of the safe-life and end-of-life creep-strain spectrum. Full-scale pressurized inflatable modules are large, costly, and difficult to experimentally study. Therefore, material subcomponents are often studied as an alternative. An experimental thermally controlled long-term creep study of VectranTM webbings for application to inflatable modules is presented. Vectran fibers have high strength and low creep properties. High strength webbing materials are desirable for the load bearing restraint layer of inflatable modules because they are strong, flexible, and lightweight. Characterization of the creep behavior, safe-life, and end-of- life of webbing specimens will help quantify comparable life properties for inflatable modules. Several experimental multiple-year creep studies of webbing specimens in uncontrolled thermal environments have been conducted at NASA Langley Research Center. Experimental data obtained exhibits the classic creep-strain curve due to load, coupled with unique sinusoidal variation due to variation in temperature and humidity over daily and annual time periods. Results also have indicated that specimens fail within a year if the applied load is greater than 50 percent of the rated load. The primary goal of this study is to eliminate thermal effects from the creep data for a group of webbing specimens, and to allow uncontrolled thermal effects to influence the creep data of a second group of webbing specimens. Comparison of both sets of data will define how temperature influences creep data. A unique creep test facility was fabricated to facilitate the generation and comparison of the two sets of data. The facility consists of five creep test stands with an integrated heating and cooling system, and four creep test stands exposed to external environmental or ambient conditions. The facility contains displacement, temperature, humidity, and load sensors. Test specimens consist of one- inch wide, 48-inch long Vectran webbings rated at 12,500 pounds-per-inch. Experimental thermally controlled creep-strain data has been generated for two groups of webbing specimens. Applied load for all test stands was above 9000 lbs and greater than 50 percent of the rated load. Temperatures varied between 58˚F and 83˚F for the four test stands exposed to ambient conditions. Associated creep data exhibited the classic creep- strain profiles. The temperature was set to 72˚F for the five test stands in the controlled temperature environment. Creep data for tests with temperature control also exhibited the classic strain profiles. Data indicated that if the load is greater n thermal effects do not manifest. Therefore, creep tests with loads less than 50 percent of the rated load are planned for in the near future.

Kenner, Winfred S.↗
DOE OSTI2022

A reinvestigation into Munson’s model for room closure in bedded rock salt

Accurate predictions of room closure are important for hazardous waste repositories in rock salt formations, such as the Waste Isolation Pilot Plant (WIPP). When Munson and co-workers simulated several room closure experiments conducted at the WIPP during the 1980’s and 1990’s, their simulated closure curves closely agreed with the closure measurements. A careful review of their work, however, raised concerns and prompted the reinvestigation in this paper. Here, to begin the reinvestigation, Munson’s legacy Room D closure simulation was reasonably recreated in a current-day finite element code. Next, special care was taken to obtain numerically converged results, re-introduce the anhydrite strata intermittently ignored by Munson, and calibrate the Munson–Dawson (M–D) constitutive model for salt as much as possible from laboratory test measurements. When this new model was used to simulate Room D’s closure, it under-predicted the horizontal and vertical closure rates by 2.34x and 3.10x, respectively, at 5.7 years after room excavation. As a result, the M–D model was extended to capture the newly established creep behavior at low equivalent stresses (<8 MPa) and replace the Tresca with the Hosford equivalent stress. Simulations using the new M–D model over-predicted the horizontal closure rate by 1.15x and under-predicted the vertical closure rate by 1.08x at 5.7 years, averaged over three room closure experiments. Although further improvements could be made, the new model has a stronger scientific foundation than Munson’s legacy model and appears ready for careful engineering use.

58 GEOSCIENCES↗
NASA NTRS2002

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines require materials that can meet high temperatures while resisting the corrosive oxidation-reduction reaction of combustion known as blanching, the main cause of engine failure. A project was initiated at NASA-Marshal Space Flight Center (MSFC) to combine three existing technologies to build and demonstrate an advanced liquid rocket engine combustion chamber that would provide a 100 mission life. Technology developed in microgravity research to build cartridges for space furnaces was utilized to vacuum plasma spray (VPS) a functional gradient coating on the hot wall of the combustion liner as one continuous operation, eliminating any bondline between the coating and the liner. The coating was NiCrAlY, developed previously as durable protective coatings on space shuttle high pressure fuel turbopump (HPFTP) turbine blades. A thermal model showed that 0.03 in. NiCrAlY applied to the hot wall of the combustion liner would reduce the hot wall temperature 200 F, a 20% reduction, for longer life. Cu-8Cr-4Nb alloy, which was developed by NASA-Glenn Research Center (GRC), and which possesses excellent high temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability, was utilized as the liner material in place of NARloy-Z. The Cu-8Cr-4Nb material exhibits better mechanical properties at 650 C (1200 F) than NARloy-Z does at 538 C (1000 F). VPS formed Cu-8Cr-4Nb combustion chamber liners with a protective NiCrAlY functional gradient coating have been hot fire tested, successfully demonstrating a durable coating for the first time. Hot fire tests along with tensile and low cycle fatigue properties of the VPS formed combustion chamber liners and witness panel specimens are discussed.

Holmes, Richard↗
NASA NTRS1979

The strainrange partitioning behavior of an advanced gas turbine disk alloy, AF2-1DA

The low-cycle, creep-fatigue characteristics of the advanced gas turbine disk alloy, AF2-1DA have been determined at 1400 F and are presented in terms of the method of strainrange partitioning (SRP). The mean stresses which develop in the PC and CP type SRP cycles at the lowest inelastic strainrange were observed to influence the cyclic lives to a greater extent than the creep effects and hence interfered with a conventional interpretation of the results by SRP. A procedure is proposed for dealing with the mean stress effects on life which is compatible with SRP.

Halford, G. R.↗
NASA NTRS1979

The strainrange partitioning behavior of an advanced gas turbine disk alloy, AF2-1DA

The low-cycle, creep-fatigue characteristics of the advanced gas turbine disk alloy, AF2-1DA have been determined at 1400 F and are presented in terms of the method of strainrange partitioning (SRP). The mean stresses which develop in the PC (tensile Plasticity reversed by compressive Creep) and CP (tensile Creep reversed by compressive Plasticity) type SRP cycles at the lowest inelastic strainrange were observed to influence the cyclic lives to a greater extent than the creep effects and hence interfered with a conventional interpretation of the results by SRP. A procedure is proposed for dealing with the mean stress effects on life which is compatible with SRP.

Halford, G. R.↗
NASA NTRS1985

The influence of cobalt, tantalum, and tungsten on the microstructure of single crystal nickel-base superalloys

The influence of composition on the microstructure of single crystal nickel-base superalloys was investigated. Co was replaced by Ni, and Ta was replaced by either Ni or W, according to a matrix of compositions based on MAR-M247. Substitution of Ni for Co caused an increase in gamma-prime solvus temperature, an increase in gamma-gamma-prime lattice mismatch, and the precipitation of W-rich phases in the alloys with high refractory metal levels. Substitution of Ni for Ta caused large decreases in gamma-prime solvus temperature, gamma-prime volume fraction, and gamma-gamma-prime lattice mismatch, whereas substitution of W for Ta resulted in smaller decreases in these features. For the alloys with gamma-prime particles that remained coherent, substitution of Ni for Co caused an increase in gamma-prime coarsening rate. The two alloys with the largest magnitude of lattice mismatch possessed gamma-prime particles which lost coherency during unstressed aging and exhibited anomalously low coarsening rates. Creep exposure at 1000 C resulted in the formation of gamma-prime lamellae oriented perpendicular to the applied stress axis in all alloys.

Nathal, M. V.↗
NASA NTRS1994

Four advances in carbon-carbon materials technology

Carbon-carbon composites are a specialty class of materials having many unique properties making these composites attractive for a variety of demanding engineering applications. Chief among these properties are exceptional retention of mechanical properties at temperatures as high as 4000 F, excellent creep resistance, and low density (1.6 to 1.8 g/cu cm). Although carbon-carbon composites are currently in service in a variety of applications, much development work remains to be accomplished before these materials can be considered to be fully mature, realizing their full potential. Four recent technology advances holding particular promise for overcoming current barriers to the wide-spread commercialization of carbon-carbon composites are described. These advances are: markedly improved interlaminar strengths (more than doubled) of two dimensional composites achieved by whiskerization of the fabric reinforcing plies, simultaneously improved oxidation resistance and mechanical properties achieved by the incorporation of matrix-phase oxidation inhibitors based on carborane chemistry, improved oxidation resistance achieved by compositionally graded oxidation protective coatings, and markedly reduced processing times (hours as opposed to weeks or months) accomplished through a novel process of carbon infiltration and coatings deposition based on the use of liquid-phase precursor materials.

Maahs, Howard G.↗
NASA NTRS1995

Rhenium material properties

Tensile data were obtained from four different types of rhenium at ambient and elevated temperatures. The four types of rhenium included chemical vapor deposition (CVD) and three powder metallurgy (PM) types, i.e., rolled sheet and pressed and sintered bars, with and without hot isostatic pressure (HIP) treatment. Results revealed a wide range of values with ultimate strengths at ambient temperatures varying from 663 MPa for CVD rhenium to 943 MPa for rolled sheet. A similar spread was also obtained for material tested at 1088 K and 1644 K. The wide variance observed with the different materials indicated that the rhenium manufacturing process, material composition and prior handling strongly dictated its properties. In addition to tensile properties, CVD, pressed and sintered material and HIP rhenium successfully completed 100 cycles of low cycle fatigue. Creep data were also obtained showing that CVD and pressed and sintered rhenium could sustain five hours of testing under a tension of 27.5 MPa at 1922 K.

Biaglow, James A.↗
NASA NTRS1997

MoSi2-Base Composite for Engine Applications

The intermetallic compound MoSi2 has long been known as a high temperature material that has excellent oxidation resistance and electrical/thermal conductivity. Also its low cost, high melting point (2023 C), relatively low density (6.2 g/cm versus 8 g/cm for current engine materials), and ease of machining make it an attractive structural material. However, the use of MoSi2 has been hindered because of the brittle nature of the material at low temperatures, inadequate creep resistance at high temperatures, accelerated oxidation (also known as 'pest' oxidation) at temperatures between approximately 400 and 500 C, and a coefficient of thermal expansion (CTE) that is relatively high in comparison to potential reinforcing fibers such as SiC. This CTE mismatch between the fiber and the matrix resulted in severe matrix cracking during thermal cycling.

Hebsur, Mohan G.↗