Nickel-200 fatigue testing for thermal fatigue data on regeneratively cooled hypersonic research engine structure

Biastre, F. A.

English

NASA Technical Reports Server

NASA CR-66842 
C O R Y  rnl lT7-0  
C 0 L p - e  
AiResearch Manufacturing Division 
1 6 s  A N G E L f S  A S  C A L I F O R N I A  
REPORT NO. AP-68-46 I 7  
TEST REPORT ON FATIGUE-TESTING OF NICKEL-200 PANELS 
HYPERSONIC RESEARCH ENGINE PROJECT - PHASE I I A  
NASA CONTRACT NO. NAS1-6666 
NO.OF PACES 16 
DATE IO January 1969 
PREPARED BY Enqineerina S t a f f  
APPROVED BY 
HRE Program Manager 
OISTRIBUTION OF THIS REPORT IS PROVIDED I N  THE INTEREST 
OF INFOWATION EXCHANGE. RESPONSI!{ILITY FOR THE CONTENTS 
RESIDES I N  THE AUTHOR OR ORGANIZATION THAT PREPARED I T .  
https://ntrs.nasa.gov/search.jsp?R=19690031651 2020-03-12T04:26:26+00:00Z
ABSTRACT 
This  r e p o r t  p re sen t s  t h e  r e s u l t s  of f a t i g u e  tests conducted 
on Nickel-200 a l l o y  t o  o b t a i n  low cyc le  thermal f a t i g u e  performance d a t a  
f o r  a p p l i c a t i o n  t o  the regene ra t ive ly  cooled s t r u c t u r e s  on t h e  Hypersonic 
Research Engine. The o b j e c t i v e  w a s  t o  determine t h e  advantages of using 
Ni-200 material as opposed t o  Hastelloy-X. The r e s u l t s  show t h a t  t h e  low 
cycle  f a t i g u e  l i f e  of t he  engine s t r u c t u r e  would be  increased  from 136 
cyc les  f o r  Hastelloy-X up t o  225 cyc les  f o r  Ni-200 a t  t h e  most severe 
design opera t ing  condi t ion.  This is  due t o  t h e  h igher  thermal condu&vity 
and h ighe r  d u c t i l i t y  of t h e  Ni-200 a t  ope ra t ing  temperature as compared 
t o  Hastelloy-X. The r e l a t i v e l y  lower creep-rupture s t r e n g t h  of t he  Ni-200 
would n o t ,  however, p e r m i t  a p p l i c a t i o n  i n  s t r u c t u r a l  p a r t s  under h igh  
mechanical stress. 
FOREWORD 
Th is  Category I Test Report i s  submitted t o  the NASA Langley Research 
Center by the  AiResearch Manufactur ing Company, Los Angeles, Ca l i f o rn ia .  
The document was prepared i n  compliance w i t h  Paragraph 4.3.3.c of NASA 
R e l i a b i l i t y  P u b l i c a t i o n  NPC250-I. 
=A=UETT AIRESEARCH MANUFACTURING DIVISION 
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Page i i  
CONTENTS 
Sect ion 
I .o INTRODUCTION 
P.0 T E S T  SPECIMENS 
~ 3.0 RESULTS AND DATA REDUCTION 
4.0 CONCLUSIONS 
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68-46 I 7  
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ILLUSTRATIONS 
Fiaure 
Plastic Strain Range vs c for Nickel-200 tot 
I 
2 Nickel-200 Fatigue Test Results 
3 Low Cycle Fatigue Test Results 
Table 
I 
2 
3 
TABLES 
Nickel-200 Sol id Bar Fixture Test Results 
Nickel-200 Plate-Fin Fatigue Test Results 
Nickel-200 Fatigue Life Calculations 
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I .  0 INTRODUCTION 
T h i s  r e p o r t  presents the  r e s u l t s  o f  f a t i g u e  t e s t s  conducted on Nickel-200 
a l l o y  specimens t o  o b t a i n  low c y c l e  fa t i gue  performance data f o r  t h i s  type 
o f  m a t e r i a l .  The p o t e n t i a l  a p p l i c a t i o n  was the  replacement o f  Has te l l oy  X 
w i t h  Nickel-200 f o r  the h o t  sur face face sheet, i n  regions o f  h igh  heat f l u x .  
The combined b e n e f i t s  o f  improved d u c t i l i t y  and markedly h igher  thermal con- 
d u c t i v i t y  were be l i eved  t o  o f f e r  dec ide l y  increased cyc le  l i f e  f o r  t he  requi red 
a p p l i c a t i o n .  
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68-46 I7 
Page I 
2.0 TEST SPECIMENS 
Solid bar and plate-fin test specimens were prepared for use in the 
mechanical bending test apparatus that was employed during the low cycle 
fatigue evaluation for NASA Contract No. NASI-5002 (Study of Regeneratively 
Cooled Panels). The solid bar specimens were two inches wide by six in. 
long, and approximately 0.235 in. thick. The plate-fin specimens used two by 
six by 0.220 in. thick Hastelloy bars that were recessed on both faces to 
accept 0.075 in. high rectangular offset fins, which were also made from 
Hastelloy X. Surface plates of 0.025 in. thick Nickel-200 material were 
applied to the specimens which were then brazed with Palniro 4 filler alloy. 
The reduced strength'of Nickel-200 necessitated the use of 0.025 in. thick 
face sheets in comparison with 0.015 in. thick for Hastelloy X, to provide 
adequate pressure containment strength. 
AlRESEARCH MANUFACTURING DIVISION 
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3.0 RESULTS AND DATA REDUCTION 
Tests  were performed a t  room temperature and a t  14OO0F on the  s o l i d  bars 
and t h e  p l a t e  f i n  specimens. 
n i c k e l  face sheet ope ra t i ng  cond i t i ons  when used as a d i r e c t  replacement f o r  
Has te l l oy  X a t  t he  M, = 8.0 design po in t .  The t e s t  specimens were subjected t o  
f u l l y  reversed bending deformations by us ing  formed mandrels o f  5, 9,  and 16 in .  
r a d i i  t o  o b t a i n  d i f f e r e n t  values o f  c o n t r o l l e d  t o t a l  s t r a i n  ampli tude. The 
t e s t  r e s u l t s  f o r  t he  s o l i d  bars  a re  presented i n  Table I and f o r  the p la te -  
f i n  specimens on Table 2. Test temperature, specimen thickness, i n i t i a l  
load, c y c l i c l y  s t a b i l i z e d  load, mandrel s i z e  and cyc les  t o  f a i l u r e  a r e  l i s t e d  
i n  these tables, f o l l ow ing .  
The 14OO0F temperature was representa t ive  o f  
Curves were developed us ing  ac tua l  room temperature and 14OO0F s t ress-  
s t r a i n  data ob ta ined from t e n s i l e  specimens. Curves were p l o t t e d  f o r  equ iva len t  
p l a s t i c  s t r a i n  ranges versus a x i a l  t o t a l  s t r a i n  range f o r  unax ia l  loading;  two- 
to-one b i a x i a l  load ing  and equ i -b iax ia l  loading. The decreased e l a s t i c  modulus 
a t  e leva ted  temperature corresponded q u i t e  c l o s e l y  t o  the decreased strenqth,  
and the  curves f o r  p l a s t i c  s t r a i n  range versus t o t a l  s t r a i n  range were found to 
be v i r t u a l l y  i d e n t i c a l  a t  room temperature and a t  14OOOF. The r e s u l t i n g  curves 
a r e  shown on F igure  I .  
The formula f o r  t o t a  I appl i ed  s t r a i n  range expressed i n  terms of mandrel 
radius, R, and specimen thickness, t, i s :  
t - - 
t o t  R + t / 2  E: 
Using t h i s  formula, t he  t o t a l  s t r a i n  ranges app l i ed  t o  the  var ious  specimens 
were computed: 
I Sol i d  Bar Specimens 
( a )  R = 5 in., h = 0.235 in.. 
0.235 
t o t  5. I I8 
= -= 0.0460 in./in. 8 
A s  = 0.0507 in. /in.. ( from F igure  1 )  
eQ 
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S p e c  i men 
No. 
I 
2 
3 
4 
5 
6 
7 
8 
9 
I O  
I 1  
12 
13 
14 
15 
TABLE I 
NICKEL-200 SOLID BAR FIXTURE TEST RESULTS 
Test Spec imen 
T F p . ,  Th i c k n e s s ,  
F in .  
amb. 0.234 
amb. 0.234 
amb. 0.234 
I400 0.235 
amb . 0.235 
I400 0.234 
I400 0.234 
I400 0.236 
amb. 0.236 
amb. 0.233 
I400 0.234 
I400 0.234 
I400 0.234 
I400 0.236 
I400 0.236 
I n i t i a l  
Load 
I b .  
22-50 
I800 
I350 
400 
I200 
450 
600 
600 
I775 
I700 
575 
600 
700 
625 
625 
; t a b  i 1 i z e d  
Load 
l b .  
- 
2200 
I600 
- 
1600 
600 
Dropped 
t o  225 
- 
2050 
600 
600 
600 
700 
625 
625 
a n d r e l  
a d i u s ,  
in .  
5 
5 
16 
5 
16 
16 
5 
16 
9 
16 
16 
9 
16 
9 
9 
:ycl es 
t o  
Fa i 1 
67 
72 
I144 
I49 
IO7 I 
223 
200 
373 
264 
287 
2 87 
65 
275 
I32 
I20+ 
Remarks 
I n s u f f i c i e n t  
l o a d  - t e s t  
i n v a l i d  
D e f e c t i v e  t e s t  
Spec imen 
p a r t i a l l y  
f r a c t u r e d  
AIRESEARCH MANUFACTURING DIVISION 
Lo5 Angels Cslilnrnia 68-46 I7 
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Specimen 
No. 
TOP 
l6 Bottom 
17 Top Bot tom 
18 Top Bottom 
19 Top Bottom 
2o Bottom 
TOP 
TOP 
2 1  Bottom 
22 Top Bottom 
23 Bottom 
TOP 
TABLE 2 
NICKEL-200 PLATE-FIN FATIGUE TEST RESULTS 
T e s t  
Temp., 
OF 
amb. 
amb. 
amb. 
amb. 
I400 
I400 
I400 
I400 
Specimen I n i t i a l  
T h i c k n e s s ,  Load 
in .  lb .  
0.269 IO00 
0.268 8 00 
0.268 800 
0.268 950 
0.268 4 50 
0.269 600 
0.270 400 
0.270 550 
AIRESEARCH MANUFACTURING DlVlSlON 
Lo5 Angeler California 
S t a b  i 1 i z e d  
Load, 
l b .  
I300 
I200 
I200 
I350 
600 
700 
550 
6 50 
Mand re1 
Rad i u s ,  
i n .  
9 
16 
16 
9 
16 
9 
16 
9 
C y c l e s  
t o  
F a i  1 
29 
26 
I32 
I 30 
I33 
131 
32 
28 
I08 
D e f e c t i v e  
44 
37 
I09 
I33 
39 
31 
68-46 I7 
Page  5 
0 0.004 0.008 0.012 0.016 0.020 0,024 0.028 
5-46516 
IN./IN. - TOTAL STRAIN RANGE 
TOT’ 
e 
F i g u r e  I .  Plastic S t r a i n  Range vs e TOT for Nickel-200 
AIRESEARCH MANUFACTURING DIVISION 
Lor Angelel Calilornia 68-46 I7 
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(b) R = 9 in.; h = 0.235 in .  
€ - -   0*235 = 0.0258 in./in. t o t  9. I18 
A€ = 0.0280 in . / i n .  (from F i g u r e  I )  
eQ 
(c )  R = 16 in.; h = 0.235 in .  
---  0'235 0.0145 in .  
t o t  16. 118 - 8 
AS = 0.0153 in . / in .  (from F i g u r e  I )  
eQ 
P l a t e - F i n  Specimens 
(a )  R = 9 in.; h = 0.270 in .  
E = -  0'270 = 0.0292 i n . / i n .  
t o t  9. 135 
Ae = 0.0315 i n . / i n .  ( f rom F i g u r e  ) 
eQ 
(b )  R = 16 i n . ;  h = 0.270 in. 
8 -  -- 0'270 0.0165 in . / in .  
t o t  16. 135 - 
A eea= 0.0175 i n . / i n .  (from F i g u r e  I )  
These p l a s t i c  s t r a i n  ranges were used i n  c o n j u n c t i o n  w i t h  t h e  t e s t  
r e s u l t s  p rov ided  i n  Tables I and 2, t o  produce t h e  g r a p h i c a l  p r e s e n t a t i o n  shown 
i n  F i g u r e  2. The s o l i d  ba r  t e s t  da ta  i n d i c a t e d  a r e d u c t i o n  i n  cyc les  t o  
f a i l u r e  a t  1400°F b y  comparison t o  t h e  RT r e s u l t s .  Nevertheless,  t h e  s lope  
o f  t h e  l i n e  f o r  p l a s t i c  s t r a i n  range vs c y c l e s  i s  steeper a t  14OO0F than a t  
RT. Extension o f  t h i s  l i n e  i n  t h e  d i r e c t i o n  o f  h i g h e r  p l a s t i c  s t r a i n  range 
would cause i t  t o  i n t e r s e c t  t h e  RT l i n e  a t  app rox ima te l y  seven pe rcen t  p l a s t i c  
s t r a i n  range (25-30 c y c l e s  t o  f a i l ) .  T h i s  i n d i c a t e s  an increase i n  d u c t i l i t y  
a t  14OO0F, wh ich  i s  c o n s i s t e n t  w i t h  t e n s i l e  data.  The s teeper  s lope  a t  14OO0F 
i s  a t t r i b u t a b l e  t o  t h e  increased creep c o n t r i b u t i o n  t o  specimen f a i l u r e  a t  
lower  s t r a i n  ranges. 
The t r e n d s  o b t a i n e d  w i t h  t h e  p l a t e  f i n  specimens were s i m i l a r  t o  s o l i d  
b a r  data w i t h  increased l i f e  a t  1400°F, a h i g h  p l a s t i c  s t r a i n  range and a 
s teeper  s lope  i n  comparison t o  RT data.  The 140OoF and RT l i n e s  i n t e r s e c t  a t  
app rox ima te l y  two p e r c e n t  s t r a i n  range (75 c y c l e s  t o  f a i l ) .  A l though n o t  e x a c t l y  
i d e n t i c a l ,  t h e  s lopes o f  t h e  RT l i n e s  for t h e  s o l i d  ba r  specimens and t h e  p l a t e  
f i n  specimens were i n  good agreement. The s lope  o f  t h e  14OO0F l i n e  f o r  t h e  
s o l i d  bars  was d e f i n i t e l y  s teeper  than  t h e  p l a t e  f i n  l i n e  a t  14OOOF. T h i s  i s  
AIRESEARCH MANUFACTURING DIVISION 
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RT TEST POINTS 
0.10 
w 0.08 
2 0.06 
2 0.04 
(3 
z 
U 
I- 
v) 
u 
U 
t;; 
4 0.02 
k2 
5 
3 0.001 
Q. 
w 
-I 
W 0.01c => 
cc 
; 0.ooc 
0.00: 
W 
\ 
z . - 
0' 
PI 
W 
Q 
0. OOi 
IO 20 40 40 80 100 
N, CYCLES TO 
x 14OO0F TEST POINTS 
F i g u r e  2. Nickel-200 
AIRESEARCH MANUFACTURING DIVISION 
Lo5 Angeles C a l h m e  
200 
FAILURE 
Fatigue 
400 600 
Test Results 
800 I000 
5-46577 
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a t  l e a s t  p a r t i a l l y  exp la inab le  by the  d i f f e r e n c e  i n  t e s t  speed w i t h  a c y c l i c  
r a t e  of two t o  f o u r  f u l l  cycles per min. on the s o l i d  bars and f i f t e e n  t o  twenty 
cycles per min. on the p l a t e  f i n  bars.  I n  add i t i on ,  a s u b s t a n t i a l l y  h igher  
c y c l e  l i f e  w i t h  the  s o l i d  bars produced more accumulated creep s t r a i n  than 
w i t h  t h e  p l a t e  f i n  bars. Both o f  these f a c t o r s  lead t o  increased cumulat ive 
creep i n  the  s o l i d  bars, and hence a steeper slope i n  the t e s t  l i nes .  
The next and f i n a l  step i n  the data reduct ion was the a p p l i c a t i o n  of  the 
t e s t  r e s u l t s  i n  F igure 2. Th is  was d i r e c t e d  toward an es t ima t ion  o f  c y c l i c  
f a t i g u e  engine 1 i f e  as a f u n c t i o n  o f  ope ra t i ng  temperature d i f f e r e n t i a l s  between 
the ho t  s k i n  and the  n i c k e l  p l a t e  f i n  ho t  face sheet. The t a s k  was accomplished 
by t a k i n g  1450'F as the reference temperature f o r  a n i c k e l  hot  ou te r  surface, 
and by computing the thermal d i f f e r e n t i a l  growth between the ho t  surface and 
the Has te l l oy  X c o l d  s t r u c t u r e  f o r  var ious AT values. The e l a s t i c  deformation 
o f  t he  c o l d  w a l l  d u r i n g  each f u l l  c y c l e  was then deducted from the  thermal 
d i f f e r e n t i a l  growth t o  o b t a i n  t h e  a p p l i e d  s t r a i n  f o r  the n i c k e l  surface. 
A l l ow ing  f o r  t he  d i f f e r e n c e  i n  metal  thicknesses o f  t he  n i c k e l  surface w a l l  
(0.025 in.)  and the  H a s t e l l o y  X prime s t r u c t u r a l  w a l l  (0.060 and a l s o  
account ing f o r  t h e  d i f f e r e n c e s  i n  the  s t reng th  o f  Nickel-200 a t  RT and 145OoF, 
the  e q u i - b i a x i a l  e l a s t i c  s t r a i n  range app l i ed  t o  the co ld  w a l l  was computed 
t o  be approximately 0.00020 in. / in.  d u r i n g  each f u l l  cycle. The thermal 
expansion f o r  n i c k e l  i n  hea t ing  up from 70' t o  1450'F was computed t o  be 
( IYAT)~ = (9.0 x 10-6) (1450 - 70) = 0.01240 in. / in.  The thermal growth of 
the co ld  w a l l  was ca l cu la ted  f o r  co ld  w a l l  temperatures ranging from 1300° 
down t o  500'F (corresponding t o  AT values from 150' t o  950'F). The thermal 
d i f f e r e n t i a l  growth was c a l c u l a t e d  as: 
A€ - ASth = (QAT)~  - ( Q A T ) ~  thermal 
The a p p l i e d  b i a x i a l  s t r a i n  range t o  the  n i c k e l  hot  surface was computed by 
s u b t r a c t i n g  the c o l d  w a l l  deformation range as fo l l ows :  
- 8 t o t  - heth - 0.00020 
The r e s u l t i n g  value f o r  e was then used t o  determine Ae from the  equi-  
b i a x i a l  curve on F igure 1 .  Since p a r t  o f  the p l a s t i c  s t r a i n  d u r i n g  each 
duty  c y c l e  occurs a t  RT and p a r t  a t  e levated temperature, a mean p e r f o r -  
mance l i n e  was added t o  F igure 2 f o r  the p l a t e  f i n  bars. This was used t o  
o b t a i n  est imated ho t  surface f a t i g u e  l i f e .  The c a l c u l a t i o n s  a r e  given i n  
Table 3. 
t o t  eQ 
These r e s u l t s  a r e  p l o t t e d  on F igure 3. Fo r  d i r e c t  comparison, 
curves a r e  a l s o  presented on t h i s  f i g u r e  showing t h e  p red ic ted  c y c l e  l i f e  
t h a t  would be achieved w i t h  a Has te l l oy  X hot  surface sheet. The thermal 
f a t i g u e  curve was based on thermal f a t i g u e  t e s t i n g  performed e a r l i e r  i n  t h e  
HRE program and reported i n  AiResearch Report AP-68-3813, The mechanical 
f a t i g u e  curve was based upon mechanical bending t e s t  data obta ined du r ing  the 
course o f  the low c y c l e  f a t i g u e  evaluation, under Contract  No. NASI-5002. 
AIRESEARCH MANUFACTURING DIVISION 
LOS Angeles Calvlornta 
68-46 I 7  
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TABLE 3 
N I C K E L - 2 0 0  F A T I G U E  L I F E  CALCULATIONS 
Eng i n e  Cold Wall 
AT, F Temper a t u  re, F 
I50 I300 
250 I200 
350 I100 
450 IO00 
550 
650 
7 50 
900 
800 
7 00 
wmc 
0.0 I070 
0.00965 
0.00870 
0.00775 
0.00680 
0.00585 
0.00495 
0.00410 
0.00330 
AIRESEARCH MANUFACTURING DIVISION 
LOS Angeles Calllornla 
t h  A8 
0.00 I 7 0  
0.00275 
0.00370 
0.00465 
0.00560 
0 a 00655 
0 - 00745 
0.00830 
0.009 IO 
TOT 
8 
0.00 I50 
0.00255 
0.00350 
0.00445 
0.00540 
0.00635 
0.00725 
0.00810 
0.00890 
0.00230 
0 .00430 
0.00620 
0.008 I O  
0.01000 
0.01 I90 
0.0 I360 
0.0 I530 
0.0 I680 
Cyc 1 es t o  
Fail, N 
> I  000 
71 000 
800 
480 
325 
235 
I80 
I45 
130 
68-46 I7 
Page 10 
400 
300 
IO0 
X 
I 50OoF) 
4 00 
5-06578 
Figure 3 .  Low Cycle Fatigue 
Test Results 
68-46 I7 
Page I I 
The apprec iab ly  h igher  s t reng th  o f  Has te l l oy  X leads t o  l i t t l e  o r  no 
p l a s t i c  f l o w  w i t h  small  temperature d i f f e r e n t i a l s ,  and the re fo re  b e t t e r  cyc le  
l i f e  than Nickel-200 w i t h  small values o f  engine AT. A t  h igher  AT, t h e  
b e t t e r  d u c t i l i t y  o f  Nickel-200 becomes the  most important s i n g l e  f a c t o r ;  i n  
s p i t e  o f  t he  somewhat h ighe r  p l a s t i c  s t r a i n  range than f o r  Has te l l oy  X a t  
t h e  same values of  AT, a g rea te r  cyc le  l i f e  i s  a t t a i n a b l e  w i t h  Nickel-200. 
The curves i n  F igure 3 r e f l e c t  t h i s  behavior. 
Nickel-200 i s  the lower AT o f  662'F (due t o  t h e  improved thermal c o n d u c t i v i t y )  
compared t o  800'F f o r  0.015-in. 
p o i n t .  The ac tua l  ope ra t i ng  p o i n t s  a r e  i nd i ca ted  on t h e  f igure,  and an 
improvement from 136 t o  225 cyc les i s  i nd i ca ted  by employing Nickel-200 i n  
p lace  of  Has te l l oy  X, a t  equal th ickness of  0.015 in. For 0.025 in .  t h i c k  
Nickel-200 face sheet, t h e  AT increases t o  723'F and t h e  l i f e  i s  reduced t o  
200 cycles.  The r e l a t i v e l y  l o w  creep-rupture s t reng th  o f  n icke l ,  however, 
would r e q u i r e  f u r t h e r  eva lua t i on  before the f e a s i b i l i t y  o f  employing n i c k e l  
i n  t h i s  a p p l i c a t i o n  can be f i r m l y  establ ished. 
Another f a c t o r  f a v o r i n g  
Has te l l oy  X face sheet a t  t he  Mach 8 design 
AIRESEARCH MANUFACTURING DIVISION 
Los Angeles Callforma 
68-46 I7 
Page 12 


Test report on fatigue-testing of nickel-200 panels

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