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At least 19 records

Turbine engine materials durability research

High temperature environmental attack of dollar intensive turbine components reduces turbine efficiency and can limit life. The mechanisms of alloy and coating attack and the effects of interaction with the environment on mechanical behavior. This base of understanding provides the foundation for developing life prediction methods and identifying strategies for controlling attack. Subjects discussed in detail include oxidation and new developments in thermal barrier coating research.

S. R. Levine

Fatigue Life of Flow-Formed Aluminum 2195 and 6061 Alloys

The successful design and fabrication of metallic cryotanks for commercial aviation applications require lightweight, durable materials capable of withstanding high pressures and cryogenic temperatures through tens of thousands of thermomechanical refueling cycles. Flow forming is an advanced manufacturing technique that offers high-rate production and scalability for fabricating integrally stiffened cylinders suitable for cryotank applications. This work establishes the durability of flow-formed aluminum alloys by characterizing their fatigue life performance under conditions that mimic cryotank refueling cycles. Residual stresses in flow-formed aluminum-lithium (Al-Li) 2195-T6 cylinders were assessed using the contour method and found to be minimal. Fatigue life testing was conducted on flow-formed Al-Li 2195-T6 at room temperature and cryogenic temperatures (-321°F [-196°C]), with wrought Al-Li 2195-T6 serving as a baseline for comparison. Results showed that flow-formed materials exhibited fatigue performance comparable to or better than wrought materials, with no statistically significant differences observed between different specimen orientations relative to processing directions. Fractography revealed reduced delaminations in the flow-formed Al-Li 2195 samples as compared to wrought, indicating potential improvement to the microstructure that could result in improved service properties. Texture analysis using electron backscattered diffraction (EBSD) indicated recrystallization during heat treatment, potentially contributing to reduced delamination susceptibility. These findings demonstrating flow-formed material durability coupled with the high manufacturing efficiency of flow forming, makes flow forming an attractive process to produce aircraft cryotanks.

EBF3

Materials technology for large space structures

Several of the key material technology needs that were identified for large space structures are outlined. They include lightweight structural materials, materials durability in the space environment, and some special aspects of materials fabrication technology. Examples of current materials research directed toward large space structures are described. Additional research needs and opportunities are noted. A short bibliography is included of selected references that describe large space structural concepts and related technology needs in detail.

Blankenship, C. P.

Combustion rig durability testing of turbine ceramics

A test facility for cyclic exposure of ceramic test bars to 1370 C has been designed as a means of the evaluation of the material durability under high-temperature cycling, particularly in heat-engine applications. The principal features of the test rig and test procedures are briefly discussed, and test results are presented for several commercial ceramics, including hot-pressed silicon nitride, carborundum sintered alpha-SiC, siliconized SiC, and reaction-bonded silicon nitride.

Carruthers, W. D.

A mature Bosch CO2 reduction technology

The reduction of CO2 is one of the steps in closing the oxygen loop for long-duration manned space missions. Several units utilizing the Bosch process, which catalytically reduces CO2 with hydrogen, have been built and operated during the past decade. Each contributed substantial information affecting subsequent designs. Early challenges were primarily concerned with carbon control, materials durability, and reliability of reaction initiation. These were followed by concern about power consumption, expendable weight, volume, and process rate control. Suitable materials and techniques for carbon containment and process reliability have been demonstrated. Power requirements have been reduced by almost an order of magnitude. Methods for significant reductions in expendable weight and volume have been developed. The technology is at a state of maturity directly applicable to designs for space missions.

King, C. D.

Starprobe thermal shield system design concepts

The mission goals, flight trajectory, and material durability requirements for the NASA Starprobe spacecraft are reviewed. The spacecraft will use a Jovian gravity assist to pass within four solar radii of the sun to study fields and particles near the sun, perform experiments dealing with relativity and gravity, and observe the structure of the solar atmosphere from the photosphere to the corona. Constraints on the system size and mass design are given, and the system is noted to be required to withstand 2500 K at perihelion, thermally insulate the instrument payload, have a tube for optical measurements, and provide protection from meteorite damage. A secondary shield is also required to dispense thermal radiation that passes the primary shield and could endanger the payload. Design options are discussed, along with temperature control requirements and a conical carbon-carbon primary shield with mass-loss rate characteristics sufficient to meet a 2.5 mg/sec criterion.

Maag, C. R.

A High Temperature Cyclic Oxidation Data Base for Selected Materials Tested at NASA Glenn Research Center

The cyclic oxidation test results for some 1000 high temperature commercial and experimental alloys have been collected in an EXCEL database. This database represents over thirty years of research at NASA Glenn Research Center in Cleveland, Ohio. The data is in the form of a series of runs of specific weight change versus time values for a set of samples tested at a given temperature, cycle time, and exposure time. Included on each run is a set of embedded plots of the critical data. The nature of the data is discussed along with analysis of the cyclic oxidation process. In addition examples are given as to how a set of results can be analyzed. The data is assembled on a read-only compact disk which is available on request from Materials Durability Branch, NASA Glenn Research Center, Cleveland, Ohio.

Scale Spalling Models

Machine tests crease durability of sheet materials

To test the crease resistance of sheet materials, the mid-section is folded over crease-control blades. One end is clamped to a motor-driven eccentric, the other to a spring, and durability is measured by the cycles required to produce failure.

Jones, L. K.

Durability of aircraft composite materials

Confidence in the long term durability of advanced composites is developed through a series of flight service programs. Service experience is obtained by installing secondary and primary composite components on commercial and military transport aircraft and helicopters. Included are spoilers, rudders, elevators, ailerons, fairings and wing boxes on transport aircraft and doors, fairings, tail rotors, vertical fins, and horizontal stabilizers on helicopters. Materials included in the evaluation are boron/epoxy, Kevlar/epoxy, graphite/epoxy and boron/aluminum. Inspection, maintenance, and repair results for the components in service are reported. The effects of long term exposure to laboratory, flight, and outdoor environmental conditions are reported for various composite materials. Included are effects of moisture absorption, ultraviolet radiation, and aircraft fuels and fluids.

H. Benson Dextern

3500-hour durability testing of ceramic materials for automotive gas turbine engines

A two-year durability program was performed by AiResearch Phoenix to evaluate four commercially available ceramic materials under simulated automotive gas turbine combustor discharge conditions. These conditions included extended cyclic thermal exposures up to 2500 F and 3500 hr. The four materials selected for evaluation were Norton NCX-34 hot pressed silicon nitride, AiResearch RBN 101 reaction bonded silicon nitride, Carborundum pressureless sintered alpha-SiC and Pure Carbon Co. (British Nuclear Fuels, Ltd.) Refel reaction sintered silicon carbide. These materials were initially exposed to 350 hr/1750 cycles at 1200 and 1370 C. Subsequent exposures to 1050, 2100 and 3500 hr were performed on those materials maintaining 50% of baseline strength after the initial exposure. Additional evaluations of exposed bars included dimensional and weight changes, dye penetrant, specific damping capacity changes, SEM fractography, and X-ray diffraction.

Carruthers, W. D.

Study of fatigue durability of advanced composite materials under conditions of accelerated loading

The effect of temperature on the tension-tension fatigue life of the T300/5208 graphite/epoxy angle-ply laminate system was investigated in an effort to develop an acceptable and reliable method of accelerated loading. Typical S log sub 10 N curves were determined experimentally at 25 C, 75 C, and 115 C. The time-temperature superposition principle was employed to find the shift factors of uniaxial fatigue strength, and a general linear equation of S log sub 10 N for shifting purpose was established. The combined techniques of cyclic creep measurements and optical microscopy upon fatigue failure allow some assessment of the possible physical basis of S log 10 N curve shifting. Before fatigue, the laminates at all test temperatures and stress levels undergo a unique damage mechanism during fatigue loading. It is concluded that an accelerated loading method is feasible.

Shih, H. M.

Monte Carlo modeling of atomic oxygen attack of polymers with protective coatings on LDEF

Characterization of the behavior of atomic oxygen interaction with materials on the Long Duration Exposure Facility (LDEF) will assist in understanding the mechanisms involved, and will lead to improved reliability in predicting in-space durability of materials based on ground laboratory testing. A computational simulation of atomic oxygen interaction with protected polymers was developed using Monte Carlo techniques. Through the use of assumed mechanistic behavior of atomic oxygen and results of both ground laboratory and LDEF data, a predictive Monte Carlo model was developed which simulates the oxidation processes that occur on polymers with applied protective coatings that have defects. The use of high atomic oxygen fluence-directed ram LDEF results has enabled mechanistic implications to be made by adjusting Monte Carlo modeling assumptions to match observed results based on scanning electron microscopy. Modeling assumptions, implications, and predictions are presented, along with comparison of observed ground laboratory and LDEF results.

Bruce A. Banks

Tests of several bearing materials lubricated by gasoline

This investigation on the relative wear of several bearing materials lubricated by gasoline was conducted at the Langley Memorial Aeronautical Laboratory, as part of a general research on fuel injection engines for aircraft. The specific purpose of the work was to find a durable bearing material for gear pumps to be used for the delivery of gasoline and diesel engine fuel oil at moderate pressures to the high pressure pumps of fuel injection engines.

Joachin, W F

Airplane dopes and doping

Cellulose acetate and cellulose nitrate are the important constituents of airplane dopes in use at the present time, but planes were treated with other materials in the experimental stages of flying. The above compounds belong to the class of colloids and are of value because they produce a shrinking action on the fabric when drying out of solution, rendering it drum tight. Other colloids possessing the same property have been proposed and tried. In the first stages of the development of dope, however, shrinkage was not considered. The fabric was treated merely to render it waterproof. The first airplanes constructed were covered with cotton fabric stretched as tightly as possible over the winds, fuselage, etc., and flying was possible only in fine weather. The necessity of an airplane which would fly under all weather conditions at once became apparent. Then followed experiments with rubberized fabrics, fabrics treated with glue rendered insoluble by formaldehyde or bichromate, fabrics treated with drying and nondrying oils, shellac, casein, etc. It was found that fabrics treated as above lost their tension in damp weather, and the oil from the motor penetrated the proofing material and weakened the fabric. For the most part the film of material lacked durability. Cellulose nitrate lacquers, however were found to be more satisfactory under varying weather conditions, added less weight to the planes, and were easily applied. On the other hand, they were highly inflammable, and oil from the motor penetrated the film of cellulose nitrate, causing the tension of the fabric to be relaxed.

PROTECTIVE COATINGS AND COVERINGS

Space environmental effects on materials

Research efforts at NASA-Langley to characterize the durability of composite materials which are candidates for use as components on various space hardware systems are reviewed. The material applications include large space structures, antennas, cables, thermal control coatings, solar reflectors, and satellite power systems. Simulation facilities have been built to study radiation effects on polymer matrix composites, and the dimensional stability of the matrix composites and tension stabilized cables. Numerical models are being developed for radiation effects on the mechanical, physical, and optical properties. Additionally, chemical and microstructural analyses are performed to identify damage mechanisms and the limits of effectiveness of accelerating life tests. It is noted that no residual strength reduction has been detected in polymer films after dosages of 5 billion rads of electron radiation.

Tenney, D. R.

Effects of commercial aircraft operating environment on composite materials

Long term effects of commercial aircraft operating environment on the properties and durability of composite materials are being systematically explored. Composite specimens configured for various mechanical property tests are exposed to environmental conditions on aircraft in scheduled airline service, on racks at major airports, and to controlled environmental conditions in the laboratory. Results of tests following these exposures will identify critical parameters affecting composite durability, and correlation of the data will aid in developing methods for predicting durability. Interim results of these studies show that mass change of composite specimens on commercial aircraft depends upon the regional climate and season, and that mass loss from composite surfaces due to ultraviolet radiation can be largely prevented by aircraft paint.

Chapman, A. J.

Reuseable lightweight modular multi-layer insulation for space shuttle

The adaptation of the Self Evacuating Multilayer Insulation System to the space shuttle orbiter liquid hydrogen tanks was investigated. Small scale material screening tests and subscale panel tests demonstrated the potential of the insulation to withstand the anticipated 100 flight cycles. The composition of the material and the process for producing the finished insulation are described. Results of the various tests to determine the durability of the material are presented.

Burr, K. F.