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28th Annual Conference on Composites, Materials & Structures Radisson Resort At the Port, Cocoa Beach/Cape Canaveral, FL

26-30 January 2004

Commercialization of NASA's High Strength Cast Aluminum Alloy for High Temperature Applications

Jonathan A. Lee

NASA-Marshall Space Flight Center (MSFC) ED33/Metallic Materials and Processes Group

Huntsville, AL 35812

J onathan.A.Lee@nasa.gov Phone: (256) 544-9290

ABSTRACT

In this paper, the commercialization of a new high strength cast aluminum alloy, invented by NASA-Marshall Space Flight Center, for high temperature applications will be presented. Originally developed to meet U.S. automotive legislation requiring low­exhaust emission, the novel NASA aluminum alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (450°F-750°F), which can lead to reducing part weight and cost as well as improving performance for automotive engine applications. It is an ideal low cost material for cast components such as pistons, cylinder heads, cylinder liners, connecting rods, turbo chargers, impellers, actuators, brake calipers and rotors. NASA alloy also offers greater wear resistance, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys, and the new alloy can be produced economically from sand, permanent mold and investment casting. Since 2001, this technology was licensed to several companies for automotive and marine internal combustion engines applications.

https://ntrs.nasa.gov/search.jsp?R=20040035597 2020-05-29T04:00:25+00:00Z

28th Conference on Composites, Materials & Structures. Cocoa Beach, FL. January 26-30, 2004

Commercialization of NASA's High Strength Cast Aluminum Alloy for High Temperature Applications

Jonathan A. Lee

NASA-Marshall Space Flight Center (MSFC) E0331Metallic Materials & Processes Group Huntsville, AL 35812

Jonathan.A.Lee@nasa.gov (256) 544-9290

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Introduction Marshall Space Flight Center -----

BACKGROUND

Originally developed by NASA as new piston alloys to meet U.S. legislation requiring low hydrocarbon emission for automotive

engines, the novel NASA alloys also exhibit great improvement in strength at elevated temperatures for many other applications.

MILESTONES

.:. 1995-1996: NASA-Fo.rd co.llabo.rative agreement to. develo.p an allo.y fo.r dual-use techno.logy under Partnership fo.r Next Generatio.n o.fVehicles (PNGV) pro.gram .

• :. 1996-1999: NASA-MSFC independently funded this alloy develo.pment .

• :. 2002: First 2 U.S. patents were issued to. NASA with several mo.re U.S. patents under pending. Fo.reign patent filing is in pro.gress .

• :. Present: Three (3) patent licenses have been granted to. private co.mpanies fo.r co.mmercial pro.ducts. On-go.ing licensing nego.tiatio.ns with several co.mpanies.

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How NASA High Strength Alloy Can Help To Reduce Hydrocarbon Emission

---------------- Marshall Space Flight Center ---

larger crevice thicker piston volume top-land

piston ring

cy linder wall

o conventional al~HHH

cast piston alloy

CONVENTIONAL PISTON DESIGN LARGE CREVICE VOLUME

(Origin of Substantial Hydrocarbon Emission)

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11-

reduced crevice thinner piston volume top-land

Stronger cast piston material is mandatory

MODIFIED PISTON DESIGN REDUCED CREVICE VOLUME

(Reduction of Hydrocarbon Emission)

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How High Temperature Strength Alloy Can Improve Piston's Functional Requirements

Functional Requirement

Improved Durability

Design Factor

low crevice volume I .1

Marshall Space Flight Center ---

Piston Feature

Different types of Material Requirements

reduced top land I ~I J -~ ] High strength

J ~I improved combustion I ~I reinforced crown I •

crown cracking I .1 high temp. strength I ~I High fatigue strength

scuffmglwear I ~I wear resistance I ~I High Silicon

reduced height ! Reduced i Friction -------~~I reduced mass I LowCTE

Reduced Noise & Vibration

Reduced Fuel intake

reduced sections

reduced mass I .1 light weight

improved stability I ~I control of fit

High specific strength

Dimensional Stability

~I reduced mass I ~I reduced sections I , High specific strength

NASA's Novel Material Development Principles for New High Strength Cast AI Alloys

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----- ---------- Marshall Space Flight Center ---

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~ Develop New Strengthening Mechanisms • Precipitates are coherent to the Al matrix. • L 12 crystal structure and low lattice mismatch. • Low cost chemistry formulations for alloy «$0.75/lb).

No Industry Infrastructure Modifications • Baseline casting process for pistons: Permanent Mold. • Can be used for sand and investment castings. • Raw material can be recycled and mass produced. • Technology can be adopted easily by any casting vendors.

Maintain Similar 300 AI-Series Properties • High hardness, wear resistance, low CTE, machining, etc. • NASA398 (Hyper-eutectic) comparable to 390 & Z16. • NASA388 (Eutectic) comparable to 384 & Mahle 124. • NASA358 (Hypo-eutectic) comparable to 356, 357.

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Strength Comparison For Piston Alloys After 100 hrs. Soaking at 600 of & Test at 600 of

Marshall Space Flight Center

No. Alloy Heat Treat Process Conditions 1. 332 T5 Permanent mold 2. 4032 T6 Forging 3. 360 F Die cast 4. 380 F Die cast S. 384 F Die cast 6. 390 TS Permanent mold 7. 413 TS Permanent mold 8. 443 F Sand cast 9. 319 T6 Sand cast 10. Z16 TS Permanent mold 11. 7075 T6 Forging 12. MSFC 398 T5 Permanent mold

2 3 4 5 6 7 8 9 10 11 ALLOYS FOR PISTON APPLICATIONS

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22

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--""'""'"- .-- ---~-- _. __ ._-- -- --~ -----

Strength Comparison For Piston Alloys After 100 hrs. Soaking at 700 of & Test at 700 of

----- ----------- Marshall Space Flight Center ---

No. Alto! Heat Treat Process Conditions 16 1. 332 T5 Permanent mold 2. 4032 T6 Forging

~ 3. 360 F Die cast

= 4. 380 F Die cast

= 5. 384 F Die cast t"--

E-i 6. 390 T5 Permanent mold

< 7. 413 T5 Permanent mold .-. 8. 443 F Sand cast ~ rJ'l 9. 319 T6 Sand cast ~ 10. Z16 T6 Permanent Mold ---= 11. 7075 T6 Forging E-i 12. MSFC 398 T5 Permanent mold ~ Z

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1 2 3 4 5 6 7 8 9 10 11 12 ALLOYS FOR PISTON APPLICATIONS

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Tensile Strength Compare With Popular 356 & 357 Alloys for NON-Piston Applications

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0' '------' 400 OF

3x stronger

500°F 600°F

.. 356-T6 sand cast c=J 357-T6 sand cast 1- _

.. NASA alloys-T5

4x stronger

5x

700 OF Test Temperature (after 100 hrs. soaking)

~ ______ ~ ___ ~o_o __ 0 __ 0 _ _ 0 0 _ 0 _ _____ ~~

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Fatigue Strength Compare With 224 Series Alloy for NON-Piston Applications

----- ----------- Marshall Space Flight Center __ _

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500 of

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.. 224-T7 Investment Cast + HIP CI 224-T7 Sand Cast .. NASA 398-TS Sand Cast

--------------------------------------------------------------9

125%

220% 6

170%

600°F 700°F 800 OF Test Temperature (after 100 hrs. soaking)

Material Selection Guide & Potential Applications

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NASA 398 (16% - 18% Si)

Permanent Mold

NASA 388 (100/0 - 130/0 Si)

Sand Cast

NASA 358 (6% - 9% Si)

Sand Cast

Marshall Space Flight Center -----

390, Zollner Z-16 Mahle 126, AE 425 AC9B, KB alloys

336,339,383,384 413, M124, 4032 2618, KS 1295

319,332,355,356, 357,359,360,380 201,206,224,242

Pistons Bearings AlC Compressors Cylinder liners Brake calipers

Pistons Cylinder blocks Cylinder heads Connecting rods Metal Composites

Jet engine parts Turbochargers Metal composites Impellers Metal Composites

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l

NASA New High Strength Cast Aluminum Alloys for High Temperature Applications

Cast Pistons

Originally developed by NASA as piston alloys to meet U.S. legislation requiring low hydrocarbon emission for internal

combustion engines, the novel NASA alloys also exhibit dramatic increase in high temperature strengths for

many aerospace and commercial applications.