NiTi Alloy Ball Bearings

60NiTi, which contains 60% nickel and 40% titanium, is a superelastic intermetallic material for use in bearings, gears, and other mechanical systems. When properly processed, 60NiTi is hard, lightweight, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, non-galling, and non-magnetic. 60NiTi was previously considered difficult to machine, partly because of issues with residual stresses and quench cracking. Modern ceramic processing methods, co-developed by NASA Glenn, now enable 60NiTi bearings to be easily manufactured. In addition, a method is available for pre-stressing the materials to increase their durability. Bearing-grade 60NiTi is manufactured via a patented, high-temperature powder metallurgy (PM) process. Pre-alloyed 60NiTi powder is hot isostatic pressed (HIPed) into various shapes and sizes depending upon the desired end product. To make 60NiTi balls, the powder is HIPed into rough, spherical ball blanks that are then ground, polished, and lapped. Because the PM process yields ball blanks that have isotropic mechanical properties, high-quality (Grade 5) ball bearings can be readily produced. The finished 60NiTi balls are bright and shiny in appearance and resemble conventional polished steel balls. The manufacture of 60NiTi balls is a fully commercialized process, and many standard ball sizes are available. The material can also be shaped into other metallic components, such as gears, sliding bearings, actuators, and drives.

SMAs are important multifunctional materials for the development of adaptive engineering structures. They exhibit a high work output that is competitive with, or superior to, conventional hydraulic, pneumatic, or electromagnetic actuators. While highly promising, SMAs are not always a practical alternative to conventional actuators because of their limited phase transformation temperatures and dimensional instability. Thanks to Glenn's innovative new SMA, that's about to change. Unlike traditional binary NiTi SMAs, Glenn's Ni-Ti-Hf-Zr SMA includes secondary, nanoscale precipitate phases that offer inherent dimensional stability to the material. Consequently, there is minimal to no need for training, resulting in much faster production times, lower processing costs, and a finished product with superior work outputs and better operational life. These Ni-rich alloys can be produced by Vacuum Induction Melting, Vacuum Arc Melting, Vacuum Arc Remelting, and Induction Skull Melting. Perhaps the most exciting characteristic of Glenn's SMA, however, is its ability to achieve a broad range of transformation temperatures suitable for high temperature (100 to 300°C), ambient, and sub-ambient temperature applications nearing -100°C. Furthermore, these temperatures can be tailored and fine-tuned though heat treatment to fit the needed parameters for the application of interest. In contrast, traditional NiTi SMAs exhibit fixed phase transformation at temperatures from slightly below room temperature to around 100°C. Glenn's Ni-Ti-Hf-Zr SMA opens the door to countless applications that can benefit from the unique properties of SMAs but require high durability and extreme temperature capability.

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.

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.

Most spacecraft feature release, retention, and deployment devices as key components, because these devices achieve on-demand configurability of solar panels, probes, antennas, scientific instruments, fairings, etc. Until now, designing and using such devices in small spacecraft has been a challenge, because their mass, volume, and power requirements are significant and can impose design constraints. CubeSats, in particular, often need to deploy several structures (such as solar arrays) simultaneously, which prior-art deployment devices have not been able to manage effectively. Glenn's innovation embeds SMAs within the components so the structures can be retained during launch, then released and deployed in orbit. The release and retention device is controlled by an SMA activated pin puller to disengage the release plate from the hooks holding the solar arrays. Once released, the SMA hinge is passively enabled to the deployed state. When ready on orbit, the mechanism is commanded to release and electrical power is sent to the SMA actuator, releasing the component to its deployed state. The component is deployed to its final position through the use of hinges, which are activated passively with SMA spring strips. The retention and release device and hinge are substantially smaller and lighter than deployment mechanisms have ever been and can deploy simultaneously with great reliability. Having already been successfully deployed on a NASA mission, Glenn's innovation is a game-changing technology for CubeSats and other small satellites.