Ivan E. Locci

Effect of growth rate on elevated temperature plastic flow androom temperature fracture toughness of directionally solidified NiAl-31Cr-3Mo

Abstract The eutectic system Ni-33A1-31Cr-3Mo was directionally solidified at rates ranging from 7.6 to 508 mm/h. Samples were examined for microstructure and alloy chemistry, compression tested at 1200 and 1300 K, and subjected to room temperature fracture toughness measurements. Lamellar eutectic grains were formed at 12.7 mm/h; however, cellular structures with a radial eutectic pattern developed at faster growth rates. Elevated temperature compression testing between 10−4 to 10−7 s−1 did not reveal an optimum growth condition, nor did any single growth condition result in a significant fracture toughness advantage. The mechanical behavior, taken together, suggests that Ni-33A1-31Cr-3Mo grown at rates from 25.4 to 254 mm/h will have nominally equivalent properties

Microstructure and phase stability of single crystal NiAl alloyed with Hf and Zr

Six near stoichiometric, NiAI single-crystal alloys, with 0.05-1.5 at.% of Hf and Zr additions plus Si impurities, were microstructurally analyzed in the as-cast, homogenized, and aged conditions. Hafnium-rich interdendritic regions, containing the Heusler phase (Ni2AIHf), were found in all the as-cast alloys containing Hf. Homogenization heat treatments partially reduced these interdendritic segregated regions. Transmission electron microscopy (TEM) observations of the as-cast and homogenized microstructures revealed the presence of a high density of fine Hf (or Zr) and Si-rich precipitates. These were identified as G-phase, Nil6X6Si7, or as an orthorhombic NiXSi phase, where X is Hf or Zr. Under these conditions the expected Heusler phase (/3 _) was almost completely absent. The Si responsible for the formation of the G and NiHfSi phases is the result of molten metal reacting with the Si-containing crucible used during the casting process. Varying the cooling rates after homogenization resulted in the refinement or complete suppression of the G and NiHfSi phases. In some of the alloys studied, long-term aging heat treatments resulted in the formation of Heusler precipitates, which were more stable at the aging temperature and coarsened at the expense of the G-phase. In other alloys, long-term aging resulted in the formation of the NiXSi phase. The stability of the Heusler or NiXSi phases can be traced to the reactive element (Hf or Zr) to silicon ratio. If the ratio is high, then the Heusler phase appears stable after long time aging. If the ratio is low, then the NiHfSi phase appears to be the stable phase.

1300 K creep behavior of [001] oriented Ni–49Al–1Hf (at.%) single crystals

Abstract A study of the 1300 K compressive and tensile creep properties of [001]-oriented NiAl–1Hf (D209) single crystals has been undertaken. Neither post homogenization cooling treatment, minor chemical variations within an ingot or from ingot-to-ingot, nor testing procedure had a significant effect on mechanical behavior; however a heat treatment which dissolved the initial G-phase precipitates and promoted formation of Heusler particles led to a strength reduction. Little primary creep was found utilizing direct measurement of strain, and a misorientation of 18° from the [001] did not reduce the creep strength. The effects of heat treatments on properties and a comparison of the flow stress–strain rate data to those predicted by the Jaswon–Cottrell solid solution hardening model indicate that the 1300 K strength in NiAl–1Hf single crystals is mainly due to precipitation hardening mechanisms.

The decrease in yield strength in nial due to hydrostatic pressure

The decrease in yield strength in NiAl due to hydrostatic pressure is examined via a comparison of the tensile flow behavior in the low strain regime at 0.1 MPa for NiAl which was cast, extruded, and annealed for 2 hr at 827 C in argon and very slowly cooled to room temperature. Pressurization to 1.4 GPa produces a subsequent reduction at 0.1 MP in proportional limit by 40 percent as well as a 25-percent reduction in the 0.2-percent offset yield strength, while pressurization with lower pressures produces a similar reduction, although smaller in magnitude.

Effect of oxidation on the mechanical properties of a NbAl3 alloy at intermediate temperatures

Although a NbAl 3 alloy containing Cr, W, and Y has excellent oxidation resistance above 1440 K, it suffers from severe environmental attack during deformation at intermediate temperatures between 900 and 1100 K. Specimens tested in constant velocity and constant load direct compression tests showed varying degrees of degradation depending on environment (i.e., air or argon), surface finish, stress, and temperature. As a result, there were corresponding differences in mechanical behavior and in the observed microstructures. At high stresses and strain rates, specimens with as-machined surfaces were brittle at and below 1100 K when tested in air but showed fracture strains above 4% when deformed in argon. However, reproducible compressive ductility of 2–3% was attained on polished specimens tested in air. At intermediate stresses, the creep curves showed sudden and periodic increases in strain before the specimens failed catastrophically after about 80 h. Microstructural examination of these specimens revealed extensive oxidation within cracks. Constant load tests conducted at lower stresses below 100 MPa showed an apparent incubation period where the change in the length of the specimen was immeasurably small. Following the incubation period, which typically lasted between 10 and 110 h depending on stress, temperature, and surface condition, specimens increased significantly in length due to oxide growth. In this case, considerable oxide spalling occurred during the course of the test, often leading to a substantial decrease in the cross-sectional area of the specimen. Microstructural observations revealed extensive cracking in the oxide layer and in the matrix, where the cracks had originated at the oxide-metal interface. The effects of environment on the mechanical properties are rationalized with the help of a schematic environmental-deformation mechanism map.

Influence of Processing on the Microstructure and Mechanical Properties of a NbAl3-Base Alloy

Induction melting and rapid solidification processing, followed by grinding to 75-micron powder and P/M consolidation, have been used to produce a multiphase, NbAl3-based, oxidation-resistant alloy of Nb-67Al-7Cr-0.5Y-0.25W composition whose strength and ductility are significantly higher than those of the induction-melted alloy at test temperatures of up to 1200 K. Attention is given to the beneficial role of microstructural refinement; the major second phase, AlNbCr, improves both oxidation resistance and mechanical properties.

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 (Ni 16 X 6 Si 7 ), where X is Zr or Hf, has been investigated. The microstructures 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 non-uniform 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 (≤10 nm) 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≥1000 K compared to binary NiAl single crystals.

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA’s efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Microstructure, Creep and Fracture Toughness of Directionally Solidified NiAl/(Cr,Mo) Alloys Modified with Hf, Si, Ta, Ti Additions

A statistical design of experiments (DOE) strategy was implemented to optimize alloys based on the Ni-33Al-31Cr-3Mo eutectic system using small amounts of potential strengthening elements (Hf, Si, Ta, Ti). Following the analysis of the DOE results, several alloys were selected for directionally solidification (DS) utilizing a modified Bridgeman technique. The as-grown alloys were microstructurally examined by optical and scanning electron microscopy. They were also evaluated for fracture toughness at room temperature and compressive properties at 1,300K. The microstructures and mechanical properties of these DS DOE alloys are discussed and compared to the directionally solidified Ni-33Al-31Cr-3Mo base composition.

Processing and microstructure of melt spun NiAl alloys

The influence of various melt spinning parameters and the effect of consolidation on the microstructure of melt spun NiAl and NiAl + W alloys have been examined by optical and electron microscopy techniques. It was found that the addition of 0.5 at. pct W to NiAl results in a fine dispersion of W particles after melt spinning which effectively controls grain growth during annealing treatments or consolidation at temperatures between 1523 and 1723 K. Increased wheel speeds are effective at reducing both the ribbon thickness and grain size, such that proper choice of both composition and casting parameters can produce structures with grain sizes as small as 2 microns. Finally, fabrication of continuous fiber-reinforced composites which used pulverized ribbon as the matrix material was demonstrated.