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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

High Strength and Compatible Aluminum Alloy for Hydrogen-Peroxide Fuel Tanks

This paper describes the development of a new high strength and Hydrogen Peroxide (HP) propellant compatible aluminum alloy for NASA Hyper-X vehicle's fuel tanks and structures. The tensile strength of the new alloy is more than 3 times stronger than the conventional 5254 alloy while it still maintains HP compatibility similar to 5254 (Class 1 category). The alloy development strategy consists of selecting certain rare earth and transition metals, with unique electrochemical properties, that will not act as catalysts to decompose liquid HP at the atomic level. Such elements will added to the aluminum alloy and the mixture will be cast and rolled into thin sheet metals. Test coupons are machined from sheet metals for HP long-term exposure testing and mechanical properties testing. In addition, the ability to weld the new alloy using Friction Stir Welding has also been explored. Currently, aluminum alloy 5254 is the state-of-the-art material for HP storage, but its yield strength is very low (420 ksi) and may not be suitable for the development of light-weight fuel tanks for Hyper-X vehicles. The new high strength and HP compatible alloy could represent an enabling material technology for NASA's Hyper-X vehicles, where flight weight reduction is a critical requirement. These X-planes are currently under studied as air-breathing hypersonic research vehicles featuring a lifting body configuration with a Rocket Based Combined Cycle (RBCC) engine system.

Lee, Jonathan A.↗
DOE OSTI2022

Optimization of metal-supported solid oxide fuel cells with a focus on mass transport

Performance of symmetric-architecture metal-supported solid oxide fuel cells was improved significantly by optimizing the catalyst infiltration process and metal support structure. Optimization of component structure and processing parameters was performed during tape-casting and fabrication of button cells. Mass transport of oxygen in the metal support was identified as a major limitation. To overcome this limitation, pore former loading and thickness of the metal support (130–250 μm) were optimized. The catalyst infiltration process was also improved by studying the impact of firing temperature (400 °C–900 °C) and infiltration cycle numbers (1–15). The maximum power density of the optimized cell was 0.9 W cm –2 at 700°C using hydrogen as a fuel, a three-fold increase over the baseline cell performance. The degradation rate of optimized cells at 550 °C, 600 °C, and 700 °C was 2%, 4.5%, and 5.5% per 100 h, respectively. Here, the phenomena of mass transport, catalyst coarsening, and chromium poisoning on the catalyst were analyzed by electrochemical impedance spectroscopy and scanning electron microscopy.

13 HYDRO ENERGY↗
DOE OSTI2025

Tensile Performance Sensitivity to Variations of Standard 17-4 PH Heat Treatments on LPBF-Produced Material

Standard heat treatments for metals of a particular composition are typically designed with the assumption of a conventional starting microstructure, such as that produced by casting or wrought processing. When applied to metals fabricated by Laser Powder Bed Fusion (LPBF) metal additive manufacturing (AM), these heat treatments can produce inconsistent performance due to the unique as-built microstructures. This study investigates how modifications to standard heat treatments for 17-4 PH steel influence the microstructure and mechanical properties of LPBF-fabricated material. Specimens were produced and subjected to varying solutionizing and homogenizing treatments followed by standard aging treatments. Microstructures were characterized using optical microscopy, Electron Backscatter Diffraction (EBSD), and X-ray diffraction (XRD), and mechanical properties were evaluated through uniaxial tensile testing. Based on these results, recommendations are provided for achieving improved wrought-like performance in LPBF 17-4 PH steel.

17-4 PH↗
DOE OSTI2021

Cost-effective, Thin-film SOFCs for Reliable Power Generation (Final Report)

The project was aimed at developing and demonstrating an advanced solid-oxide fuel cell (SOFC) technology to cost-effectively and reliably generate electricity directly from hydrocarbon fuels (e.g., natural gas and coal-derived syngas) for distributed and central generation applications. The studied technology was built on a planar, porous metal-supported SOFC (MS-SOFC) with a unique thin-film structure having its anode intimately supported on a metal substrate. The porous metal support with graded porosity was fabricated from a low-cost scalable phase-inversion tape casting method. Anode, thin-film electrolyte, and cathode were sequentially deposited on the porous metal substrate using atmospheric plasma spray (APS). In this study, it was shown that the composition of the casting slurry could significantly influence the morphology of the metal support fabricated using the phase-inversion tape-casting method. Increasing the solid loading in the slurry favored the formation and growth of finger-like pores to a point, but the presence of excessive solid loading increased the viscosity of the casting slurry, restraining the growth of finger-like pores. With the increase in the amount of the binder polyethersulfone (PESf) in the slurry, well grown finger-like pores and a thin sponge-like layer were formed. Since the parameters of the APS process have a significant effect on the microstructure of coatings, which in turn affects or determines the SOFC cell performance, a series of metal-supported solid oxide fuel cells with a four-layer cell configuration of 430L/Ni-ScSZ/ScSZ/LSCF have been fabricated by a combination of phase inversion tape casting and APS techniques. Electrochemical testing of the cells fabricated from different deposition APS conditions revealed significant differences in cell performance.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2001

One-step Tape Casting of Composites via Slurry on Fiber

A process by which metal matrix composites can be made was presented. The process involves putting a powder slurry on fibers to make a precursor green tape. These green tapes are cut, stacked and hot pressed to form the fully dense composite. A computer program was presented which enables complete quantification and control of the process. Once some easily obtained properties of the slurry and its behavior are determined (such as the shrinkage from the wet to green state, and the density of the green tape) modification of the fiber spacing and blade height give the maker precise control of fiber volume fraction, and fiber architecture in the composite. The process was shown to be accurate and flexible through the production of a wide variety of volume fraction fiber composites made from a wide variety of fibers and powders. The most time consuming step of the tape casting process (other than hot pressing) was winding the fiber on the drum. The tape casting techniques developed resulted in high quality metal matrix composites, with ultimate tensile strength in the range of 215 ksi (1477 MPa), a strain at failure of 1.15 percent, and in fatigue at room temperature 0 to 120 ksi, n = 0.3 Hz, a 4-ply Ti-24Al-11Nb/SCS-6, 32 vol% fiber tape cast composite lasted 202,205 cycles with a maximum strain on the 100th cycle of 0.43 percent.

deGroh, Henry C., III↗
NASA NTRSDate not supplied

Analysis of Additively Manufactured Inconel 718 Combustion Behavior in Promoted Oxygen Environments

Promoted combustion testing is a vital tool for engineers to establish the combustion and flammability characteristics of materials (metallic or otherwise) in oxygen enriched environments. Historically, much of the established data for metallic promoted combustion has been with regards to cast and wrought forms. However, with the emergence of additive manufacturing as a preferred method of fabrication, the need exists to evaluate how metals in that form behave. This paper will serve as a review of the work that has been done and an analysis of the nickel-based superalloy Inconel 718, a material popular for aerospace applications such as liquid fueled rocket components and turbine engines. Promoted combustion testing (per the ASTM G124 standard) was conducted on samples of both wrought and selective laser melted fabrication, to provide comparison of flammability response between materials produced by each manufacturing method. Additionally, post-build treatments were applied to test samples to identify any effects on performance provided by hot isostatic pressing, oxygen-getting wrap during HIP, stress relieving, and solutionizing/aging heat treatments. This study will utilize optical and scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, and metallography to identify the differences in behavior of additively manufactured and wrought Inconel 718.

Additively Manufactured↗
NASA NTRS1993

Property enchancement of polyimide films by way of the incorporation of lanthanide metal ions

Lanthanide metal ions were incorporated into the polyimide derived from 2,2-bis(3,4-dicarboxyphenyl) hexafluoropropane dianhydride (6FDA) and 1,3-bis(aminophenoxy) benzene (APB) in an attempt to produce molecular level metal-polymer composites. The lanthanide series of metal ions (including aluminum, scandium, and yttrium) provide discrete and stable metal ions in the 3+ oxidation state. Throughout the series there is a uniform variation in ionic size ranging from 50 pm for aluminum to a maximum of 103.4 pm for cerium and gradually decreasing again to 84.8 pm for lutetium. The high charge-to-size ratio for these ions as well as the ability to obtain large coordination numbers makes them excellent candidates for interacting with the polymer substructure. The distinct lack of solubility of simple lanthanide salts such as the acetates and halides has made it difficult to obtain metal ions distributed in the polymer framework as discrete ions or metal complexes rather than microcomposites of metal clusters. (Lanthanum nitrates are quite soluble, but the presence of the strongly oxidizing nitrate ion leads to serious degradation of the polymer upon thermal curing. This work was successful at extending the range of soluble metals salts by using chelating agents derived from the beta-diketones dipivaloylmethane, dibenzoylmethane, trifluoroacetylacetone, and hexafluoroacetylacetone. Metal acetates which are insoluble in dimethylacetamide dissolve readily in the presence of the diketones. Addition of the polyimide yields a homogeneous resin which is then cast into a clear film. Upon curing clear films were obtained with the dibenzoylmethane and trifluoroacetylacetone ligands. The dipavaloylmethane precipitates the metal during the film casting process, and hexafluoroacetylacetone gives cured films which are deformed and brittle. These clear films are being evaluated for the effect of the metal ions on the coefficient of thermal expansion, resistance to atomic oxygen, and on selective gas permeability. Much more commonly than above, polyimide films are prepared by casting the film as the poly(amic acid) precursor which is then converted to the imidized form during the thermal cure cycle. Very limited success was achieved in the past in adding lanthanide metal ions to the amide precursors because of gellation and lack of solubility. With the use of the diketone ligands cited above, the solubility and gellation problems were overcome. However, the films after curing were clear but unacceptably brittle. Attempts to overcome this cure embrittlement problem are in progress.

Thompson, David W.↗
DOE OSTI2024

System and method of making a cast steel alloy crankshaft having low porosity

Systems and methods of making a cast steel alloy crankshaft for an internal combustion engine are provided. The method comprises providing a mold of the crankshaft. The mold has cavities to form the crankshaft. The method further comprises melting a first metallic material at between 1400 degrees Celsius (° C.) and 1600° C. to define a molten metallic material. In addition, the method further comprises feeding the molten metallic material at a riser connection angle of between 30° and 75° in the cavities of the negative sand cast mold. The method further comprises cooling the molten metallic material at a solidification time of between 5 seconds (sec) and 20 sec in the negative sand cast mold with at least one chill member to define a solidified metallic material having dimensions of the cast steel alloy crankshaft. Furthermore, the method comprises separating the solidified metallic material from the negative sand cast mold to define the cast steel alloy crankshaft.

Wang, Liang↗
DOE OSTI2024

Covalent Triazine-Based Frameworks with Ru-tda Based Catalyst Anchored via Coordination Bond for Photoinduced Water Oxidation

Light-induced water splitting (hν-WS) for the production of hydrogen as a solar fuel is considered a promising sustainable strategy for the replacement of fossil fuels. An efficient system for hν-WS involves a photoactive material that, upon shining light, is capable of separating and transferring charges to catalysts for the hydrogen and oxygen evolution processes. Covalent triazine-based frameworks (CTFs) represent an interesting class of 2D organic light-absorbing materials that have recently emerged thanks to their tunable structural, optical and morphological properties. Typically, catalysts (Cat) are metallic nanoparticles generated in situ after photoelectroreduction of metal precursors or directly drop-casted on top of the CTF material to generate Cat-CTF assemblies. Here, in this work, the synthesis, characterization and photocatalytic performance of a novel hybrid material, Ru-CTF, is reported, based on a CTF structure featuring dangling pyridyl groups that allow the Ru-tda (tda is [2,2':6',2'“-terpyridine]-6,6'”-dicarboxylic acid) water oxidation catalyst (WOC) unit to coordinate via covalent bond. The Ru-CTF molecular hybrid material can carry out the light-induced water oxidation reaction efficiently at neutral pH, reaching values of maximum TOF of 17 h -1 and TONs in the range of 220 using sodium persulfate as a sacrificial electron acceptor.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

In situ monitoring of microstructure evolution during thermal processing of uranium-zirconium alloys using laser-generated ultrasound

In this study, laser-generated ultrasound was used to monitor microstructure evolution during thermal processing of as-cast, polycrystalline binary uranium-zirconium metallic fuel alloys with compositions of U-20wt.%Zr (U-20Zr), U-50wt.%Zr (U-50Zr) and U-80wt.%Zr (U-80Zr). Ultrasonic waveforms were recorded during heating and cooling the samples from room temperature to >973 K and back. A phase transition temperature for all three compositions was estimated from the temperature at which an abrupt and rapid reduction in ultrasonic velocities was observed. Microstructural features on the length scale of tens of micrometers were inferred from the observation of scattering of ultrasonic waves by elastic heterogeneities above ~823 K in U-20Zr, while a hysteresis in the ultrasonic velocities of U-80Zr upon cooling was attributed to a partial retention of the high temperature phase following thermal annealing. The U-50Zr alloy exhibited a reversible viscoelastic response above 933 K, as evidenced by the observation of high frequency attenuation of the shear component of the waveforms at high temperature. Ultrasonic measurements were supplemented by in situ transmission electron microscopy (TEM). The TEM images revealed that the δ-U-Zr matrix in the three compositions underwent a spinodal decomposition above ~823 K into nanoscale regions. The ultrasonic measurements revealed larger, micron-scale structure evolution in the U-20Zr alloy at the same temperature. This large-scale structure is associated with heterogeneous regions having different Zr content. Our findings show the potential heating rate dependence of microstructural evolution in U-Zr alloys and highlight differences in the thermomechanical response and associated length scales during thermal annealing between single- and dual-phase compositions. These results demonstrate the utility of laser ultrasonics to rapidly and efficiently scan phase boundaries and monitor micrometer-scale structure evolution in metallic fuel alloys.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2001

Particle Engulfment and Pushing (PEP): Past Micro-Gravity Experiments and Future Experimental Plan on the International Space Station (ISS)

The interaction of an insoluble particle with a growing solid-liquid interface (SLI) has been a subject of investigation for the four decades. For a metallurgist or a material scientist understanding the fundamental physics of such an interaction is relevant for applications that include distribution of reinforcement particles in metal matrix composites, inclusion management in castings, and distribution of Y2Ba1Cu1O5 (211) precipitates (flux pinning sites) in Y1Ba2Cu3O7 (123) superconducting crystals. The same physics is also applicable to other areas including geological applications (frost heaving in soils) and preservation of biological cells. Experimentally this interaction can be quantified in terms of a critical growth velocity, Vcr, of the SLI below which particles are pushed ahead of the advancing interface, and above which the particles are engulfed. Past experimental evidence suggests that this Vcr is an inverse function of the particle radius, R. In order to isolate the fundamental physics that governs such a relationship it is necessary to minimize natural convection at the SLI that is inherent in ground based experiments. Hence for the purpose of producing benchmark data (Vcr vs. R) PEP is a natural candidate for micro-gravity experimentation. Accordingly, experiments with pure Al containing a dispersion of ZrO2 particles and an organic analogue, succinonitrile (SCN) containing polystyrene particles have been performed on the LMS and USMP-4 mission respectively. In this paper we will summarize the experimental data that was obtained during these two micro-gravity missions and show that the results differ compared to terrestrial experiments. We will also discuss the basic elements of our analytical and numerical model and present a comparison of the predictions of these models against micro-gravity experimental data. Finally. we will discuss our future experimental plan that includes the ISS glovebox and MSRRl.

Sen, Subhayu↗
NASA NTRS2004

Aluminum-Alloy-Matrix/Alumina-Reinforcement Composites

Isotropic composites of aluminum-alloy matrices reinforced with particulate alumina have been developed as lightweight, high-specific-strength, less-expensive alternatives to nickel-base and ferrous superalloys. These composites feature a specific gravity of about 3.45 grams per cubic centimeter and specific strengths of about 200 MPa/(grams per cubic centimeter). The room-temperature tensile strength is 100 ksi (689 MPa) and stiffness is 30 Msi (206 GPa). At 500 F (260 C), these composites have shown 80 percent retention in strength and 95 percent retention in stiffness. These materials also have excellent fatigue tolerance and tribological properties. They can be fabricated in net (or nearly net) sizes and shapes to make housings, pistons, valves, and ducts in turbomachinery, and to make structural components of such diverse systems as diesel engines, automotive brake systems, and power-generation, mining, and oil-drilling equipment. Separately, incorporation of these metal matrix composites within aluminum gravity castings for localized reinforcement has been demonstrated. A composite part of this type can be fabricated in a pressure infiltration casting process. The process begins with the placement of a mold with alumina particulate preform of net or nearly net size and shape in a crucible in a vacuum furnace. A charge of the alloy is placed in the crucible with the preform. The interior of the furnace is evacuated, then the furnace heaters are turned on to heat the alloy above its liquidus temperature. Next, the interior of the furnace is filled with argon gas at a pressure about 900 psi (approximately equal to 6.2 MPa) to force the molten alloy to infiltrate the preform. Once infiltrated, the entire contents of the crucible can be allowed to cool in place, and the composite part recovered from the mold.

Kashalikar, Uday↗
DOE OSTI2023

Casting and Characterization of U-50Zr

Uranium alloyed with 50 wt% zirconium (U-50Zr) is a proposed light water reactor (LWR) nuclear fuel by Lightbridge Corporation (LTBR). The proposed method for making the U-50Zr alloy is to arc-melt master alloys and then remelt in a vacuum induction melter (VIM) to consolidate the material and cast into an intermediate shape. After casting, the material will eventually need to be formed into a desired fuel shape. The work discussed in this report resulted from a joint effort between Ltbr and Pacific Northwest National Laboratory (PNN) to investigate a 500g – 1kg scale casting process to produce the U-50Zr alloy in the desired δ-UZr 2 phase and characterize the impurities and microstructure that result from the casting process. Master alloys were fabricated in an arc melter, then five castings were carried out in a VIM with multiple inert coating and crucible materials to find an appropriate combination. Both ZrO 2 and graphite crucibles were used and different combinations of Y 2 O 3 , CaZrO 3 , and TiC to identify which would contain the molten metal with the least reaction. On each casting, the C, O, N, H impurities were analyzed as well as the phase by x-ray diffraction and microstructure. Of the five castings, two resulted in majority of δ-UZr 2 phase-pure material and had impurity levels within acceptable ranges. The two most successful castings utilized a graphite crucible with a TiC undercoating and a Y 2 O 3 overcoat. The O and N levels were below 1000 ppm and the C content was variable but did not result in measurable carbide formation. The highest success casting resulted in an average of 282 ppm C, 567 ppm O, 217 ppm N and 79 ppm H. This casting's crucible and inert coating material was repeated with slightly different casting parameters and resulted in higher C numbers but similar phase identification. The differences between each casting are discussed and recommendations are made for future experiments to better decide on a casting process to go forward with.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1998

High-Strength Aluminum Casting Alloy for High-Temperature Applications (MSFC Center Director's Discretionary Fund Final Project No. 97-10)

A new aluminum-silicon alloy has been successfully developed at Marshall Space Flight Center that has a significant improvement in tensile strength at elevated temperatures (550 to 700 F). For instance, the new alloy shows in average tensile strength of at least 90 percent higher than the current 390 aluminum piston alloy tested at 500 F. Compared to conventional aluminum alloys, automotive engines using the new piston alloy will have improved gas mileage, and may produce less air pollution in order to meet the future U.S. automotive legislative requirements for low hydrocarbon emissions. The projected cost for this alloy is less than $0.95/lb, and it readily allows the automotive components to be cast at a high production volume with a low, fully accounted cost. It is economically produced by pouring molten metal directly into conventional permanent steel molds or die casting.

Lee, J. A.↗
NASA NTRS2006

Covering a Crucible with Metal Containing Channels

In a procedure that partly resembles the lost-wax casting process, a crucible made of a brittle material (ceramic, quartz, or glass) is covered with a layer of metal containing channels. The metal cover and the channels can serve any or all of several purposes, depending upon the application: Typically, the metal would serve at least partly to reinforce the crucible. The channels could be used as passages for narrow objects that could include thermocouples and heat-transfer strips. Alternatively or in addition, channels could be used as flow paths for liquid or gaseous coolants and could be positioned and oriented for position- or direction-selective cooling. In some cases, the channels could be filled with known gases and sealed so that failure of the crucibles could be indicated by instruments that detect the gases. The process consists of three main steps. In the first step, a pattern defining the channels is formed by wrapping or depositing a material in the desired channel pattern on the outer surface of the crucible. The pattern material can be a plastic, wax, low-ash fibrous material, a soluble material, or other suitable material that can subsequently be removed easily. In a proof-of-concept demonstration (see figure), the crucible was an alumina cylinder and the mold material was plastic tie-down tape. In the second step, the patterned crucible is coated with metal. In one variation of the second step, a very thin layer containing or consisting of an electrically conductive material (e.g., gold, silver, or carbon) is painted or otherwise deposited on the mold-covered crucible, then the covering metal required for the specific application is electrodeposited on the very thin conducting layer. In another variation of the second step, the metal coat is formed by chemical vapor deposition. In the proof-of-concept demonstration, a layer of nickel 0.003 in. ( 0.08 mm) thick was electrodeposited. In the third step, the patterned material is removed. This is generally done by heating the crucible assembly until the patterned material melts and runs out, vaporizes, and/or decomposes to an ash, leaving the channels. Alternatively, if the patterned material is soluble, it can be removed by use of a suitable solvent. In the proof-of-concept demonstration, the tape was burned away by heating the assembly to a temperature of 600 C.

Grugel, Richard N.↗
NASA NTRS1984

The movement of particles in liquid metals under gravity forces and the interaction of particles with advancing solid-liquid interface

The problems of shrinkage and gas porosity are discussed. Gravity forces enhance the removal of gas bubbles from a metal melt and contribute to the feeding of shrinkage porosity in castings. Experiments are reviewed which determine how large a density difference is required for metal particles to float or sink in a metal melt and to what extent do factors not considered in Stokes Law influence particle movement in a real system. As to the interaction of particles with an advancing solid-liquid interface, the results indicate that the metal particles are not rejected in a metal melt, and that concentrations of particles in a metal following solidification are due to other factors.

Weinberg, F.↗
NASA NTRS1990

In-situ scanning electron microscope studies of crack growth in an aluminum metal-matrix composite

Edge-notched specimens of a cast and extruded Al alloy-based, alumina particulate-reinforced composite in the annealed condition were tested in situ in a SEM apparatus equipped with a deformation stage permitting the direct observation of crack growth phenomena. Fracture in this composite is seen to proceed by initiation of microcracks ahead of the macrocrack; as deformation proceeds, the microcracks lengthen, and crack propagation occurs when the region of intense plastic straining becomes comparable to the macrocrack-microcrack distance. The sequence is then repeated.

Manoharan, M.↗
NASA NTRS2000

Low Cost Al-Si Casting Alloy As In-Situ Composite for High Temperature Applications

A new aluminum-silicon (Al-Si) alloy has been successfully developed at NASA- Marshall Space Flight Center (MSFC) that has significant improvement in tensile and fatigue strength at elevated temperatures (500 F-700 F). The alloy offers a number of benefits such as light weight, high hardness, low thermal expansion and high surface wear resistance. In hypereutectic form, this alloy is considered as an in-situ Al-Si composite with tensile strength of about 90% higher than the auto industry 390 alloy at 600 F. This composite is very economically produced by using either conventional permanent steel molds or die casting. The projected material cost is less than $0.90 per pound, and automotive components such as pistons can be cast for high production rate using conventional casting techniques with a low and fully accounted cost. Key Words: Metal matrix composites, In-situ composite, aluminum-silicon alloy, hypereutectic alloy, permanent mold casting, die casting.

Lee, Jonathan A.↗