Abnormal Grain Growth Suppression in Aluminum Alloys

Via this NASA innovation, a product is first heated to a temperature within the range of 204 to 343 degrees C for an extended soak of up to 16 hours. The product is then slowly heated to a second temperature within the range of 371 to 482 degrees C for a second soak of up to 12 hours. Finally, the product is slowly cooled to a final soak temperature of 204 to 343 degrees C before cooling to room temperature. The product so treated will exhibit greatly improved formability. To date, the low formability issue has limited the use of lightweight Al-Li alloys for large rocket fuel tank dome applications. Manufacturing a dome by stretch forming typically requires multiple panels as well as multiple welding and inspection steps to assemble these panels into a full-scale fuel tank dome. Complex tensile and bending stresses induced during the stretch forming operations of Al-Li alloys have resulted in high rates of failure for this process. To spin form a large rocket dome, the spin blank must be prepared by joining smaller plates together using friction stir welding. However, friction stir welding produces a distinct metallurgical structure inside and around the friction stir weld that makes it very susceptible to cracking during spin forming.

Glenn researchers have optimized how shape memory alloys (SMAs) are trained by reconceptualizing the entire stabilization process. Whereas prior techniques stabilize SMAs during thermal cycling, under conditions of fixed stress (known as the isobaric response), what Glenn's innovators have done instead is to use mechanical cycling under conditions of fixed temperature (the isothermal response) to achieve stabilization rapidly and efficiently. This novel method uses the isobaric response to establish the stabilization point under conditions identical to those that will be used during service. Once the stabilization point is known, a set of isothermal mechanical cycling experiments is then performed using different levels of applied stress. Each of these mechanical cycling experiments is left to run until the strain response has stabilized. When the stress levels required to achieve stabilization under isothermal conditions are known, they can be used to train the material in a fraction of the time that would be required to train the material using only thermal cycling. As the strain state has been achieved isothermally, the material can be switched back under isobaric conditions, and will remain stabilized during service. In short, Glenn's method of training can be completed in a matter of minutes rather than in days or even weeks, and so SMAs become much more practical to use in a wide range of applications.

Ultrasonic Stir Welding is a solid state stir welding process, meaning that the weld work piece does not melt during the welding process. The process uses a stir rod to stir the plasticized abutting surfaces of two pieces of metallic alloy that forms the weld joint. Heating is done using a specially designed induction coil. The control system has the capability to pulse the high-power ultrasonic (HPU) energy of the stir rod on and off at different rates from 1-second pulses to 60-millisecond pulses. This pulsing capability allows the stir rod to act as a mechanical device (moving and stirring plasticized nugget material) when the HPU energy is off, and allowing the energized stir rod to transfer HPU energy into the weld nugget (to reduce forces, increase stir rod life, etc.) when the HPU energy is on. The process can be used to join high-melting-temperature alloys such as titanium, Inconel, and steel.

NASA's new Ni-based superalloy uses a powder metallurgy (PM) composition that inhibits the deleterious gamma-prime to gamma-phase transformation along stacking faults during high temperature creep deformation. Ni-base superalloys have excellent high temperature properties, mostly due to the presence of coherent precipitates. At higher temperatures, these precipitates are defeated by the diffusional shear dislocations producing intrinsic and extrinsic faults. Recent studies have found that, during deformation of turbine disk alloys at high temperature, Co, Cr, and Mo segregate to these faults (removing Ni and Al) inside the strengthening precipitates of these alloys. This represents a local phase transformation from the strengthening precipitate to the weaker matrix phase. Therefore, this elemental segregation significantly weakens the ability of a precipitate to withstand further deformation, producing faster strain rates in the alloy at higher temperatures. This invention presents a solution to prevent this type of segregation along these two faults to improve the creep properties of turbine disks and similar Ni-based alloys. By alloying a specific amount of eta phase formers (Ti, Ta, Nb, and Hf), the phase transformation to can be eliminated along 2-layer extrinsic stacking faults (SESFs) in precipitates without precipitating bulk eta phase. Also, by adding a certain amount of D019 formers (Mo and W), the phase transformation to can be mitigated along 1-layer intrinsic stacking faults (SISFs) without producing bulk sigma phase. This alloy composition incorporates both strengthening methods for use in jet turbine disks, though the composition has applications in other high-stress and/or high-temperature environments as are found in power plants, space launch systems, and other critical structural applications.

This innovation allows the incorporation of metal matrix composite reinforcing material into a metallic structure as part of the structures fabrication process. It does not require secondary processing that may affect the structures mechanical properties. It does not require bonding agents that would limit the benefits of the reinforcing material. It adds reinforcement to only the specific regions of the structure that need enhanced strength, stiffness, and/or damage tolerance, thereby allowing for more efficient design and reduction in structural weight.