WADC TR 54-206 April 1954 THERMAL-SHOCK INVESTIGATION T. A. Hunter L. L. Thomas A, R. Bobrowsky United. States Air Force Wright Air Development Center Wright-Patterson Air Force Base, Ohio

1949-3-F Prepared by Engineering Research Institute University of Michigan for Contract No. AF 33(038)-21254

TABLE OF CONTENTS LIST OF FIGRES iv LIST OF TABLES ABSTRACT vi SUMMARYii INTRODUCTION 1 OTHER INVESTIGATIONS 3 THEORETICAL ANALYSIS 3 APPROACH TO THE PROBLEM 5 APPARATUS6 SPECIMEN 17 TEST PROCEDURE 23 CRACK DEFINITION 23 ATERIALS 25 RESULTS 29 General 29 Early Work 29 Second Phase 35 Recent Work 33 DISCUSSION OF RESULTS 47 Material Comparison 47 Thermal-Shock Parameter Correlation 47 Effects of Temperature 48 Type of Crack 50 CONCLUSIONS 50 BIBLIOGRAPHY 52 APPENDIX 55 Key to Wiring Schematic55 Component Parts of Thermal-Shock Apparatus 56 Miscellaneous Capital Items 57 Power Transformer (Specifications) 57 Key to Test Log 58 Test Log 60 WADC TR 54-206 iii

LIST OF FIGURES Figure Page la. Photograph of Cracks in Vane of a Nozzle Diaphragm. 2 lb. Photograph of Three-Vane Assembly from the Nozzle Diaphragm from Which Fig. la Was Taken. 2 2a. Original Test Setup —Cooling Nozzle Directed at Specimen. 7 2b. Original Test Setup —Test Frame and Control Panel. 7 35 Original Test Setup 8 4. Interior of Old Test Rig Showing Setup with Two Specimens. 8 5. Details of Setup with Radiation Pyrometer and Specimen Supports. 9 6. Compressive Plastic Flow Produced by Tests in Rigid Specimen-Nozzle Holders. Specimen No. 39 (top) and No. 43 (bottom), about 2X scale. Specimen No. 39 shows the face at which the air jet pointed, whereas Specimen No, 43 shows the face adjacent to the cooled face, 10 70 Fronit View of Specimen Holder, Specimen, Air Nozzle, and Radiation Pyrometer, (Old Rig). 10 8t Exterior of Sound-Minimizing Chamber Surrounding Test Rig. 11 9,' View of Specimen Holder with Measuring Telescope in Position to View Specimen, 11 10. Control Panel (WADC, Modified). 12 1.1 Control-Panel Assemblies 13 12a. Operating Unit, View above Deck, 14 12b. Operating Unit, View below Deck. 14 12c. Precision Nozzle, Throat Side, 15 12d, Precision Nozzle, Back Removed to Show Water Channels 15 13. Automatic Camera Setup, 16 14. Helium Test Apparatus. 17 15. Thermal-Shock Specimen of Round Cross Section, Showing Grooves after Test; Type 347 Stainless Steel. 18 16, Thermal-Shock Specimen of Square Cross Section. 18 17, Diamond-Shaped Specimen of Type 304 Stainless Steel, Fractured during Overheating in Thermal-Shock Test. Axial load was caused by lower electrode and grip. 19 18. Thermal-Shock Specimens of Hollow-Cut Cross Section. Top specimen is Type 547 stainless steel; botton specimen is Inconel. 20 19.6 Thermal-Shock Specimen, 20 20. Triangular Specimens with Thermocouple Holes. 21 21. Fatigue Specimen. 21 22. Low-Speed Fatigue Machine (1800 rpm). 22 253 Enlargement of One Frame of Automatic 35-mm Camera Film Strip Showing Crack in Kennametal Type K-152 B, Specimen No. 2 at 261 Cycles. 24 24a, Specimen Showing Severe Oxidation. Visual crack inspection is difficult, Three cracks are present. Inconel, 1800~F. 26 24b. Kennametal Type 152 B No. 4, Showing Complete Fracture and Burning. 26 25a. Mechanical Crack in Type 304 Stainless Steel in Vicinity of Rupture Failure. XlOO. 27 25b, Thermal Crack in Type 304 Stainless Steel, XlOO. 27 25c. IN-5, 1819 Cycles, 100X. 28 25d. IN-7, 4706 Cycles, 100X, 28 WADC TR 54-206 iv

LIST OF FIGURES (cont,) Figure Page 26. HS-21 at 2000~F after 673 Cycles, 32 27. Waspalloy at 2000~F after 784 Cycles. 32 28, Comparative Thermal-Shock Resistance —Temperature 16000F. 34 29. Comparative Thermal-Shock Resistance —Temperature 1700~F. 35 30. Comparative Thermal-Shock Resistance —Temperature 1800~F. 36 31. Comparative Thermal-Shock Resistance —Temperature 1900~F. 37 32, Comparative Thermal-Shock Resistance —Temperature 2000~F. 38 33. Thermal-Shock Resistance —Nickel-Base Alloys. 42 34. Thermal-Shock Resistance -Iron-Base Alloys. 43 355 Thermal-Shock Resistance —Cobalt-Base Alloys. 44 36. Thermal-Shock Resistance —K-151-A and K-152-B Cermets. 45 37. Thermal-Shock Resistance —Battellalloy, 46 38. Hastelloy C at 2000~F, Air-Cooled for 291 Cycles. 49 39, Hastelloy C at 2000~F, Helium-Cooled for 624 Cycles. 49 A-1. Schematic Wiring Diagram of Test Rig. See Key. 54 LIST OF TABLES Table Page I, Thermal-Shock Resistance at 1600~F 359 II. Thermal-Shock Resistance at 1700~F, 39 II. Thermal-Shock Resistance at 1800~F, 40 IV. Thermal-Shock Resistance at 1900~F. 40 V. Thermal-Shock Resistance at 20000F. 41 VI* Decreasing Order of Thermal-Shock Resistance, 51 WADC TR 54-206 v

ABSTRACT Fourteen materials have been examined for their relative resistance to severe repeated thermal shock in the temperature range from 1600 to 20009F, using a suitable specimen shape developed during the evaluation. It was found that thermal shocking by itself would produce cracking in all the materials tested. WADC TR 54-206 vi

SUMMARY A program of investigation has been undertaken to evaluate the resistance of various materials to thermal shocking, A preliminary analysis of thermal-shock damage has been carried out on a theoretical basis. The results of this theoretical work indicate that the scope of the problem is so wide that purely analytical methods must be supplemented by experimental data. An experimental program has therefore been set up to test several selected materials. Suitable apparatus has been constructed which gives reasonable reproducibility of results. A standard specimen shape has been devised after considerable experimentation. Excursions into the subjects of previous specimen history, mechanical fatigue, and thermal wiggling have been made. WADC TR 54-206 vii

FINAL REPORT THERMAL-SHOCK INVESTIGATION INTRODUCTION Design of the turbine buckets is one of the most important problems of modern aircraft gas turbines. This design problem is complicated by the presence of high mechanical stresses, high temperatures, and a fatigue component. It is important that a reasonable method be found for bucket design, since the durability of the buckets appears to be one of the critical factors in the determination of the limiting overhaul time for the gas turbine aircraft engine. The usual approach to bucket design is based on known centrifugal stresses interpreted from data on the short-time elevated-temperature tensile strength, creep rate, and stress-rupture life of the material. Until recently fatigue effects have usually been neglected because of lack of information about the fatigue-producing mechanism in the engine. Thermal effects can be included in the design if the operating temperatures of the turbine can be found; but this has been done only roughly and in a few cases, Little attempt has been made to consider the effects of stress concentrations in bucket design. Stress raisers such as lateral cracks are known to be absent from the buckets, prior to their use, by virtue of 100-percent inspection of such parts before assembly. However, it has been shown by experience that cracks are initiated and developed in turbine parts during operation, These cracks act as stress raisers in three ways, first by furnishing a stress concentration, second by reducing the net section of material and thereby raising the nominal stress, and third by acting as surfaces for the growth of oxides which force the cracks open. Further, cracks may serve to nucleate fatigue failures. It has been observed that cracks have formed in the operation of turbine blades. These service cracks have been found to be distributed in such a manner that mechanical stresses alone would not have caused them to appear These cracks indicate that the leading edges of turbine blades operate in tension, that the tension is almost uniform, and that cracks can be produced by repeated thermal straining. Examination of certain nonrotating parts of gas turbines also revealed cracks which could not have been mechanical in origin (see Figs. la and lb). WADC TR 54-206 1

Fig, la, Photograph of Cracks in Vane of a No0zze Diaphragm, _............._.. Fig, lbb. Photograph of Three-Vane Assembly from the Nozzle Diaphragm from Which Fig, la Was Taken, WADC TR 54-206 2

In the light of this information, the Wright Air Development Center decided to sponsor research on the resistance of materials to repeated and severe thermal stressing. The basic test apparatus had been assembled by the Wright Air Development Center and was loaned to the University of Michigan for use. This basic apparatus has been redesigned and improved by several modifications. It uses an electrical resistanceheating cycle of 60-second duration followed by a cold-air-blast shock-cooling cycle of 5-second duration, This operation has an effect on the specimen which is reasonably similar to that produced on a turbine blade during a flame-out or start-up in an aircraft. This research was conducted at the University of Michigan Engineering Research Institute from April, 1951 to April, 1954. OTHER INVESTIGATIONS Previous investigations of cracking by thermal stress can be classified on the basis of the ductility of the material tested., Nortonl and Lidman and Bobrowsky2 worked on brittle ceramic materials. Whitman and others3 investigated metals which had a "reasonable" ductility. Avery and Matthews4 studied brittle castings. The work done on metals in reference 5 used a water coolant, a condition which does not prevail in gas turbine operation; therefore, this work was not considered strictly applicable to the present case, It is understood that others are working on the thermal-shock problem concurrently with the present investigation; the Climax Molybdenum Company at Detroit, Allison Engine Division of General Motors Corporation at Indianapolis, General Electric Company at Schenectady, Allegheny Ludlum Steel Company, and the National Advisory Committee for Aeronautics are all reported to be interested in this problem. THEORETICAL ANALYSIS Since thermal shock is essentially a problem in heat transfer, the effects of conduction, convection, and radiation must be considered immediately. In the type of test which uses a blast of cold air to provide the thermal shock, the most important means of heat transfer is convection. Conduction is not negligible however, as a considerable amount of heat is drawn from-the specimen into the water cooling system in the grips at the ends of the test piece. It is recognized that for the test piece, the ratio of the convection heat loss to the conduction heat loss is not so high as the same ratio for similar material in the shape of a turbine bucket because of the relatively larger conduction loss for the test piece. To allow for this, the velocity of the air blast has been made as high as possible (Mach 1) to maximize the convection effect. The effects of radiation are considered to be very small in contrast to conduction and convection and are ignored for both the test piece and the turbine bucket. In addition to the heat-transfer effects, certain specific properties of the materials must also be taken into consideration in evaluating thermal-shock WADC TR 54-206 3

resistivity. Such factors as thermal-expansion coefficient, Poisson's ratio, yield point at the working temperature, thermal diffusivity, thermal conductivity, and ductility are involved in the analysis, Apparently, the material which develops the smallest thermal stress in proportion to the yield-point stress will be the best material in thermal-shock resistance, Such a material would then have a high thermal conductivity and diffusivity to prevent localized steep thermal gradients, a low expansion coefficient to reduce the thermal strains, a high yield stress and ductility to permit the maximum thermal stresses to be resisted, and a small value for Poisson's ratio to reduce lateral strains to a minimum, Generally, these specific properties of the material are most influential in the initiation of a crack in a thermal-shock specimen. Once a crack has been started, however, the phenomenon changes from crack initiation to crack propagation, Corrosion resistance and oxidation are also of importance. It is known that single thermal shocks do not produce cracking in ductile materials and that the failure must therefore be progressive. Closely related factors are fatigue resistance and the deterioration of mechanical and metallurgical properties immediately prior to crack formation. It has been thought that the mechanism of mechanical fatigue and the mechanism of thermal fatigue are probably related. In summary, the analysis of the problem may be set down in terms of the groups of variables which may be expected to affect the thermal-shock resistance of a material, The first group constitutes the external conditions of the test. These are usually referred to as the boundary conditions and are External temperatures Velocity of coolant Properties of coolant Specimen dimensions Time A second group of variables consists of the thermal, mechanical, and metallurgical properties of the material. These are Thermal Properties Mechanical Properties Metallurgical Properties Specific heat Elastic modulus Structure Thermal diffusivity Poisson s ratio Composition Emissivity Stress rupture Stresses and strains Thermal conductivity Fatigue strength Chemical reaction Thermal expansion Creep Surface separations Yield strength Ductility WADC TR 54-206 4

APPROACH TO THE PROBLEM Unfortunately, several of the twenty-two variables are related, and may even be related in several ways. It is believed that the combinations of external boundary conditions and material properties give rise to certain changes which lead to the production of micro-cracks and subsequent failure by fatigue. It does not appear feasible to analyze the thermal-shock phenomenon in terms of each of the twenty-two separate factors; therefore, the common approach of lumping several items together has been used in accordance with the method of concomitant variations. All the external conditions have been taken as a unit by deciding on a certain size and shape of specimen for all tests, using a common coolant (air at 85 psi), and setting up a definite time sequence for all testing operations. The temperature of the specimen is the only variable in this group. Of the thermal properties, only the conductivity and the expansion coefficient are thought to be important quantities in thermal shock. The metallurgical properties are largely dependent on previous conditions and are not subject to control in a series of subsequent experiments; therefore they are ignored. Of the mechanical properties, only the stress-rupture and fatigue-strength variables are considered for correlation with test results, Variation of any of the properties during the shocking process has not been considered. Using this basic analysis as a reference, the attack on the problem was focussed on the following items: 1 The development of a reliable thermal-shocking apparatus using compressed air as the coolant. 2. The invention of a reasonably reproducible test, including a reasonable definition of thermal-shock failure, 53 The production of an ordered list of the thermal-shock resistances of various materials. It is realized that the experimental method proposed cannot yield the fundamental parameters of the deterioration phenomenon which leads to cracking under thermal-shock conditions. However, it is possible, by experimental means, to obtain information of much practical use in the determination of economic overhaul inters vals and in the evaluation of the merits of various materials. In this report most of the data are intended to serve as a datum for the thermal-shock resistance of a given material. This datum has been obtained by evaluating the material without previous exposure to stresses, fatigue, or elevated stress-temperature pretreatment. It was hoped that a certain amount of work could be done on the deterioration process which accompanies failure by thermal cracking. It was planned to test the materials under both thermal-shock and stress-rupture conditions in order to produce WADC TR 54-206 5

thermal-shock failure in a given number of cycles. An arbitrary number of cycles, about 100, was chosen for a working basis. Time did not permit any evaluations. Impact tests to measure deterioration could not be used, since they depend on bulk properties of the material and only a small portion near the shocked edge of the test specimens suffered appreciable deterioration. Rotating-beam fatigue tests required preparation of an excessive number of specimens and, thus, were impracticable, APPARATUS The testing rig which was originally used on this work was borrowed as a unit from Wright Air Development Center and subsequently altered a number of times to fit the immediate needs of the studies. Four new testing units were assembled using the Wright Air Development Center unit as a model, but incorporating extensive modifications,. Basically the units consist of two components, an operating part and a control part. The operating part holds the specimen, heats it as desired, cools it with an air blast, and has equipment for observing the specimen from time to time. The control unit contains the timers for maintaining uniformity of the heating and cooling cycles, temperature-regulating devices, power-supply controls, and a cumulative-cycle counter* The testing cycle consists of a 1-minute heating period followed by a 5-second cooling blast of air. The specimen is heated by using the secondary circuit of a step-down transformer. Local heating of the test section results from a reduction in the area of the test piece at the test section, thus providing a higher local resistance for the heavy flowing currents. Control of the time of the heating cycle is obtained by setting a variac manually to fix the input voltage to the primary side of the transformer at such a value that the maximum desired specimen temperature is reached in one minute. The end of the heating cycle is determined by a Wheelco control which is actuated by a radiation pyrometer. When the pyrometer measures a specimen temperature corresponding to the setting of the Wheelco control, the heating current stops and the air blast turns on for 5 seconds. The duration of the air blast is controlled by an electric timer, At the end of 5 seconds the air blast is stopped, the heating current begun again, and the cycle repeated4 The original equipment is shown in Figs. 2a, 2b, and 3. The first alterations were the addition of a plenum chamber to improve the uniformity of the velocity of the air blast, and enlargement of the piping to reduce friction losses during the blast cycle. Also, a second operating setup was installed in the original test frame (Fig. 4), In this new device the temperature of the specimen was measured by a total-radiation pyrometer, instead of the thermocouple previously used, since the drilling of a thermocouple hole in the specimens had proved troublesome, and the hole also acted as an undesired stress raiser. A further change was made at this time by integrating the air nozzle with the specimen holder as shown in Fig. 5. This resulted in better alignment of the air blast with the edge of the piece being tested. At this same time it was noted that WADC TR 54-206 6

/.Cooling nozzle I......x: *s... s. _S. pecimen Water-cooled::-: t3electrode Supporting bars a, Cool.ing Nozzle Direct;ed at Specimen. ttp........own.......tran..sformer. Tem perature indicator:~.~~~ I~~~;~~~~~~~ 1and controller illQ|___|;~iiliii~iijljj jij~BCycle counter'tetp-wer ariable'transformer b, T est Frame and Control Panel, Fig, 2. Original Test Setup. WAI)C Jta 5-20o6 y

Step-down t transformer.......................................:'Accumulator:::::::R Fig. 5:000000. Oril0_ginl Tes Setp...... -;;;; _...........- W a~ Fik.Jnterio of Old letigShowingSetupuecimen WigA BJ.. OrigTnal est Setup0 Transformers Iravet s ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~av F~~~~~t~~~ ~g. O~Itriginal01 TestRiShig Setupwih.qoSpcmn WAC - - __ —06 = 1 ~~~~~~~~~~....!.... L~evers........... F~~~F~~g io Xt}-ter~~~~~~~~~~~tor of ()ld M~~~~~~~~~~~est:R+1>E7: Sho-xtn; Setu? sr1;h rA+O SpeeimerS.~~~~~~~~~~~~~~~~~~~~~~.............. NA rl t 5}p 206 8~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~.......

Radi.ati.on Pyronmcter Nozzle Support resulting in the arrangement shown in Fig, 7, This figure also shows a change from a flattened-tube type of air nozzle to a precision movable-wall type, This new nozzle provided for adjustment of the air velocity to about Mach 1, as determined by Schlieren mieans, Use of this nozzle required the construction of a sound-deadening chamber to surround the entire operating portion. This consisted of a framework filled with batts of slag wool (Fig, 8), The final addition to the operating'rig was'the installation of a telescope to pernmiit the observation of the specimen during a test (F.i.g 9). The control panel had to be rebuilt to accommoda'te two sets of controls; it is shown in Fig. 1.0, It was soon realized that the use of only two test units would unduly prolong the investigations. The construction of four additional units was therefore begun, with the design btsed on the modified WADC equipment, A completely new design was worked out to permit rack mounting of the control equipment, as shown in Fig, 11. The operating rigs were redesigned to pe rmit easier the rmal expansion to take place, and the nozzles were provided with water-cooling passages, (Figs. 12c and 12d). Refi nements were included which permitted more accurate positioning of the specimen, and the installa'tion of automatic recording caiera equtipent to allowt 2S-hour-pnerday operation (Figs, 12 and 1 ), WADC TR 54-206 9

Grooved Cracks Cracks Fig. 8 6, ConmpressIve Plast;ic Flow Produced by Tests in Rigid tSpecimen-N.ozzle HIolders, Specimen No, j39 (top) and No. 4j (bottom), about 2X scale, Specimen No, 39 shows the face at which the air Jet pointed, whereas Specimen No, v5 shows the face adjacent to the cooled face, ScS~ ae~-~' Radiation Pyrometer. i p....... Prame Fig. 7e F'ront Vi.ew of Specimen Hlder Specimen Air Nozzlc, and Radiatio n Pyronmter, (Old Rig). WADC T 54al -206 10 j

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Exterior of Olound-Ml.nimizing Chwifber Surrounding Test Rig......................................................................................................................... Radiation Pyrometer....................................................................................................................... 1.1.11.1- 11111''I'll......................................................... -''I'll'',................................................................... I'll I''I'll,.............. Specimen......................................................................................................... I............. -1 —-............................................ I I I - -.................................... rip Holder 4:i: zzle Frame Micrometer ]mob.Telescope.....................................................................................................................................................................

Temperature Controllers Electric al Meters Timers Fig. 10. Control Panel (WADC, Modified) WADC TB 5t-20 16

Temperature and~,~~~~~~~~~ reset k~Indbicator and Cycle counter //1~Controll~er and reset knob' C l Voltmeter, Voltage regulator and pilot L, ghts Control switches and circuit breakers FigW 1oC Contro L-ane0 A1sseablies. WADC TR 54~-206 13

Badiation i~ i, |pyrometer Grip Spec imen -- sup...port arms - _ _l | _ e z _ - ^ _ i.. _.g~~~~~~~~~~~~~~gS.-E_.s....E.000200 —EE~~~~~~~~............................. NozzlIe I......... Movazle block Fig, 12ao Qperating Unit, View above Deck, _ * W-^ -:- - -..............f. Poer - i'.. "...-, 9:::::::S"''' ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~..... _z;5j ~~~~~~~~~~~~Air relay _ _ t < ~~~~~~~~~~~and valve........................ Aif r -transformer hose to nozzle >:~f lt~ ~~~ ~~~ ~~ff~~~~~gj 9. s.:g.B-. < fg~~~~~~~~~~~~~~~~~~~~g g s ss: -:: X.:.i E f~~~~~~~~~~~................... Nozzlecooling _water _ r,,G...........c o ln................g,,:water Fig, 12bo Operating Unit, View below Deck, WADC TB 51v -206 ]k

FigO l2cI, Precision Nozile, Throat Side4 Fig, 12d,^ Precisioni Nozzle^ Ba.,ck Removed to Show Water Channels, WAI)C TR ~5)i-206 1.5

Fig, 15, Automatic Camera Setup, Water cooling of the nozzles was necessary because of the closeness of the nozzle or:if ice to the heated specimen. It was found that radiation from the specimen was sufficient to heat the brass parts of the nozzle to such a temperature that the dimensions oS the orifice would change appreciably and affect the performance of the air blast, The hot nozzle parts also adversely affected the uniformity of the air blast, since they had to be cooled by the air at the beginning of each blast, By keeping the 0nozzle at a, uniform temperature with cooling water, beoth.these adverse effects were reduced appreciabbly, On one series of tests helium gas was used as the cooling medium, Tanks of the gas were connected to one of the p].lenumn chambers as shown in Fig, 14, and a plastic liner was applied to the inside of the sound-deadening chamber to reduce the escape of gas during the tests, A schematic diagram and parts AliAst for the operating and control units are included in the appendix, WABC TR 54 206 16

Fig, 14, Heliumn Test Apparatus, SP ECIMPN One of the primary problems in th.is research was the design of a suitable test specimen, To be satisfactory, the specimen had to yield reasonably reproducible results, be si-mpl.e to prepare, permit accurate temperature determinations while a test was in progress, and permit easy detection of cracks, The basic form of the test piece chosen was a cylindrical rod about 1/2 inch in diameter and from 7 to 9 inches in length. The center porti.on of this piece was then machined to a desired cross section. Removal of materia in the machining process provided the necessary local increase of electri catl resistance to develop local heating of'the test section, Several cross-section shapes were investigated, A round section was first chosen because of its simplicity. As shown:in Fig, 1].5j such a section does not possess any sharp edges; hence the tendency for a shallow crack to develop into a groove is pronounced, Thi.s grooving act+ion made accurate crack detection very difficult, and po:inted to the development of a eross section with a sharply defined edge. rThe use of an edge of fini te rwidth permitted a more accurate definition of cracking by setting an arbitrary standard of crack length. When a crack had progressed across the given edge, usually about 0,050 to 0,Ot0O inch, it was said to be complete and failure by cracking WADC TR 5v-206 17

Fig, 1-5 Thermal-Shock Specimen of Round Cross Section, Showing Grooves after Test; Type 547 Stainless Steel. to have occurred. Next a specimen of square cross section was developed and proved relatively easy to make. However, crack detection was still troublesome and the reproducibil ity was poor. This type of test piece is shown in Fig. 16. Fig 6.1.6 Thermal-Shock Specimen of Square Cross Section, WADC TR 54-206 18

From the square section it was learned that an edge sharper than a;rig)ht angle was needed. This indicated that a triangular, diamond-shaped, or hollow-ground section might work, The hollow-ground specimen gave easily detectable cracks, but this shape was so hard to manufacture to specifications that it was abandoned, The diamond shape also gave easy crack detection, but it was very hard to measure the temperature of such a specimen with a radiation pyrometer. Hollow-ground and diamond shapes are shown in Figs, 17 and 18, the triangul~ar shape was finally developed and used throughout'the remainder of the'tests. This final specimen shape is shown in Fig, 19, It could be made at reasonable cost, permitted easy crack detection, and allowed temperature measurement by mounting the specimen so -that -the back face was perpendicular to the sight line of a radiation pyrometer. In some of the early work the temp'erature was measured by inserting a thermocouple into a hole which was drill.ed along the axis of the piece. This hole was very difficult to drill in materiails as hard as some of those tested, In addition, it acted as a stress raiser and -thus interfered with'the reproducibility of results, Some of these pieces with center holes are shown in Fig, 20, Fa'tigue specimens were occasionally employed to determine mechanical properties at high stresses and room temperature., Figure 21 il.lustrates the shape of specimen used for this purpose. Some thermal- shock specimens were also prefatigued before shocking The same machine (Fig., 22) was used for both types of fatigue work, It has a special low-speed drive to avoid overheating of the pieces, and loads the pieces in pure bending by the addition of dead weights. Fig.,l 17,o Disamond4Shaped Specime. n of Type j04 Stai nless Steel, Fractured during Overheating ain Thermal-Shock Test, Axial load was caused by lower electrode and grip, WADC TR 54-206 19

Fig~. ]8, The rma[-Shock Specimens of Hollow-Cut Cross Section. Top specimen is Type 547 stainless steel; bottom specimen is Inconel, _:..... -------- EC A......................... *w' --.............-i~. eda-,^ ^s? f*^^ y^^^A^ j..... Fig,. 1-9, herma.-Shorck Specimen WADC TR 514-206 20

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....................~~~~~~~~~~~~~~~~~~~~~~~~ii~~~ii.......... ~ ~ ~ I...........~a BS................................~ii~ii~ii~i.................. ~ ~...................................( 1~800 r~m ) WAI)C'IR 54-%OL1 22~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~.......1........

TEST PROCEDURE The first step in conducting a test is calibration of the radiation pyrometer against a special specimen of the material under consideration which has an additional thermocouple, The specimen, after possible mechanical or thermal pretreatment, is then measured for edge width, inserted in the water-cooled chucks, and positioned in the holder. The radiation pyrometer is sighted on the back side of the specimen. The air nozzle is adjusted to give proper impingement of the air against the edge of the test piece, and the heating voltage is adjusted by setting the variac to give a 1-minute heating cycle. Any variations in the line voltage are compensated by manual adjustment of the variac. Thermal shocking is continued until a crack has formed and progressed across the measured edge width, defined as constituting a failure, In some cases failure by other means than cracking occurs, such as softening and sagging, upsetting, or gross erosion. These actions are allowed to bontinue to the point where the air blast no longer strikes the specimen at the proper place or angle, When failure by some means has taken place, the specimen is removed from the test stand and the thermocouple specimen is reinserted for final calibration of the heat eye, The test temperature is taken as the-mean of the initial and final calibration temperatures. Usually the final calibration temperature is higher than the initial temperature, due to contamination of the heat eye lens by dirt from the air blast. On most tests the development and progress of a crack are easily visible with a 5X telescope. On some runs, however, the crack appears during the night or over a week-end period when no operator is on duty. In such cases an automatic recording camera is installed to take a picture of the specimen during each thermal shock, The time of the shock and the number of the shock are also recorded on the film strip, as shown in Fig,: 23. CRACK DEFINITION In the process of developing a suitable specimen shape it became apparent that some sort of definition of what constitutes a failure would be needed. Failure was defined in terms of the cracking phenomenon, and thus the meaning of the term crack had to be set forth specifically, The actual formation of a crack is presumably a process by which some combination of stress, temperature, and surroundings causes some of the specimen material to separate from its immediate neighbors by a distance which exceeds a few molecular diameters. After this initial separation has taken place the phenomenon of cracking changes from one of formation to one of growth, WADC TR 54-206 23

~~:X~iiiiliiiliiililiiiili~~~~~li............ i~~i~~~Xl~~i:~ii~~iiiii~~l iiililiiili........ Xi::ii:.::E:::::'~~~::'':::':B:''~~~'~...................... ~~iiiililiiiiililiiiiiijjljijijii'ijiji ~ ~ ~ ~ ~ ~ ~ ~ ~...............................i~ii i,i8 ~ ~iilX ~liiiiiiiiiii~ii:~Fi~iii~i~ ii~iiii............................. -- -.-.................. I ----............... ~ ~ ~~~i~'~~;ii~~~i' j................... Fig, =13, li~~~nlnr~~rr~~s~n-t;...................................... C~~neru, P~lm Str~kl~ Showl~ng Cs........................... K-I~~j~ B, Spiccinexl No. 2 at 261............ w~~~~~~i~~~~~c Tri Ij4~~~~~~~~~~~~~~~~~~~~......................

It is possible to recognize a crack by optical inspection methods only when it has grown to such a size as to be visible on the surface when viewed under reasonable magnification. Moreover, the crack must differ from the normal surface finish of the specimen in shape, texture, or size if it is to be noticed. It is therefore convenient to define a crack as a recognizable gap of a certain minimum length, realizing that such a gap is a combination of both initial separation and subsequent growth. In this work the minimum length has been taken as the width of the edge of the specimen, 0.030 to 0.040 inch. This definition proved suitable for all materials except the stainless steels, which had a tendency to form grooves, rather than cracks, and thus obscure the cracks. Occasionally a crack would become filled with an oxide, which made it difficult to notice that a crack was present when the specimen was cold. In most cases, however, such oxides could be recognized as a dark line. In a typical case the crack could be seen with a 5X telescope during the air-blast portion of the cycle. The crack opened up when the air was turned on and then closed again as heating progressed. There were a few cases of tests at high temperatures in which formation of scale on the surface of the specimen made it almost impossible to decide if a crack was present (see Fig. 24a). In those cases the specimens were subjected to a metallographic examination. Occasionally a specimen cracked unexpectedly early in the test, and the cracks were not found until after they had progressed beyond the defined limits, In such instances an estimate of the number of cycles to failure was made. One material, Kennametal, cracked in an unusual manner; the specimen broke completely into two pieces within a few cycles after the crack was initiated. Such a material was subject to very strong local heating in the region of the crack because of the increase of local electrical resistance at that place. For the last few cycles before complete rupture the material was subject to actual burning where contact was still maintained (see Fig. 24b). Figures 25a, 25b, 25c, and 25d show the types of cracks developed by mechanical fatigue and thermal shock. It will be noted that in the thermal-shock crack there is little disturbance of the grain structure, except at the crack itself, and that the edges of the crack are not so sharp as those of the mechanical crack. The progress of the thermal crack seems to have been straight across the specimen, and was transgranular rather than following the grain boundaries. The sharp point on the end of the thermal crack is obviously a region of very high stress concentration. MATERIALS The materials which were tested in this program were special high-temperature metals. Classification of the types of materials may be made on the basis of the compositions. Basic groupings are: WADC TR 54-206 25

...................................................................Fl.g, 2)ta-, Spec-ImeP Showi.ng Severe Ox-id,!-ttion. Visual crack inspection'is difficult. Three cracks are present. Inconel, -800*Fo....................................................................................................... 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Cermets Iron Base Nickel Base Cobalt Base K 151 A N-155 Waspalloy HS-21 (cast) K 152 B 304 Stainless Steel Hastelloy C S-816 (cast) 310 Stainless Steel Inconel S-816(wrought) 347 Stainless Steel Nimonic 80-A M-252 Five specimens of a special chromium-rich alloy, Battellalloy, were also examined. An attempt was made to test copper, but no satisfactory method of heating copper was found. RESULTS General Results or Inlis inveszigaslon may se cavided roughly into three portions. In the early stages of the work the primary emphasis was on a theoretical analysis, The twenty-two relevant factors were examined, and the direct brute-force attack abandoned as impractically difficult. The experimental means of attack were then considered and a series of exploratory tests was run to get some idea of the limits of temperatures to be expected, specimen shapes, and methods of cooling. The second phase of the work included such areas of study as the effects of temperature, prior fatigue damage, cold work, and thermal wiggling on thermalshock resistance. In addition, a considerable effort was made to secure reproducibility of results. The third stage of the program involved an extensive evaluation of the fourteen materials examined* New testing apparatus was constructed and over 200 tests run on thermal-shock resistance of materials without previous mechanical history, but under varying temperature conditions. Early Work As a beginning a theoretical attack was made on the problem in the hope that a dimensional analysis would yield some fundamental and useful parameters for the thermal-shock phenomenon. Brittle ceramic materials had been treated in this manner and suggested this attack for metals. It was found that twenty-two variables were involved and a few excursions into the theory of dimensions showed that the direct brute-force method could not yield much useful information. For this reason it was decided to use an experimental approach. This decision was the first important result. WADC TR 54-206 29

In setting up the experimental program it was realized that several questions had to be answered before any really useful data could be expected. Most of these questions centered on the technique to be used. The technique was already fairly well defined by the equipment which was loaned by Wright Air Development Center, but the specimen shape to use, the temperature limits within which testing should be done, and the type of coolant to use remained to be selected. The development of the standard specimen has already been described. Its design constituted the second important result. Concurrently with the tests to establish a workable specimen, work was conducted to find the temperature ranges for thermal heating. If the temperatures were too low, the testing time became exceedingly long and the conditions would not simulate turbine conditions accurately enough, Investigations showed that actual turbine temperatures were in the neighborhood of 16000F, and tests on Inconel showed that such a testing temperature gave reasonable numbers of thermal-shock cycles to failure when applied to the standard specmen It was decided to test frth specimens in the temperature ranges of 1600~ up to 1800~F. To reduce the number of cycles, and thus shorten the testing time, this was later revised upward to 20000F as authorized by Wright Air Development Center. The choice of coolant was determined by the operating conditions within an actual turbine, To duplicate these conditions the coolant had to be gaseous in nature, and compressed air was the obvious choice of- medium, In order to get a cooling rate which would be high enough to make the test a true thermal shock, it was decided that the air should be applied through a nozzle at 85 psi. The design of this nozzle went through several stages and resulted in a high-precision rectangular-orifice type with movable walls to permit adjustments. The efflux velocity of the air was made as nearly Mach 1 as possible, as required by the theoretical analysis. Later developments in the nozzle design included a provision for water cooling to prevent dimensional changes by heat radiated from the test piece, A certain amount of testing of materials under conditions of combined axial stress and thermal shock was undertaken. These tests were of a preliminary and exploratory nature, intended to establish the limits for the axial load values to be used. The results were so scattered that it was realized that the thermal-shock resistance would first have to be established for conditions of no axial stress before the combinedloading condition could be investigated. For this reason the combined-loading program was set aside with the intention of resuming it at a later time. It may be well to point out that this work still remains to be done. Second Phase In the second phase of the investigation several features of thermal-shock resistance in the absence of axial stresses were examined, Among these were the possibility of producing the thermal cracking by thermal means alone, the effect of changes in testing temperature, effects of prior mechanical-fatigue damage, effects of prior cold-work, reproducibility of results, and the nature of thermal crack. WADC TR 54-206 30

Consideration of the production of cracks by purely thermal means led to the conclusion that such cracking must be a manifestation of progressive deterioration of the properties of the material. While there are some materials, usually brittle in nature, which can be cracked by a single severe quenching, the usual metals do not develop a thermal strain equal to the failure strain even when completely confined and cooled by as much as 2000~F. There was a question, then, as to whether repeated thermal shocking would develop the necessary deterioration of properties to permit cracking to develop in the absence of axial load, Several tests on HS-21, S-816, and N-155 established that it was possible to induce cracking by thermal shocking alone. Increases in the maximum cycle temperature were also investigated and were found to result in a lowered resistance to thermal shock for most materials. The increases in temperature were made in 1000F steps from 1600~ to 2000~F. At some of the higher temperatures, however, the material became so soft that plastic yielding was developed, This resulted in upsetting, sagging, and changes of shape so severe that failure was said to have occurred by means other than thermal cracking. In a turbine the blades would be so badly distorted that power output would be seriously affected, (See Figs. 26 and 27.) Since the initiation of a crack is thought to be the result of the separation of a few particles by a few molecular distances, it would appear that either mechanicalfatigue damage or thermal-shock damage should have nearly the same effects on thermalshock resistance. To test this hypothesis several specimens were run in thermal shock after having been prefatigued in a low-speed (1750-rpm) rotating-beam fatigue machine. Only a few samples of this kind were tested and the results were not conclusive except to indicate that prefatiguing reduced the sensitivity of the specimen to variations in edge width when tested in thermal shock. It is still thought that tests on prefatigued specimens should be made in order to find the correlation, if any, between mechanical and thermal damage. Another type of mechanical damage which could easily be investigated was that due to cold-working of the material. Several Inconel specimens were subjected to cold-working of 1, 5, and 10 percent before thermal shocking. There was no significant change in the thermal-shock resistance with this cold-working. After it was established that cracking could be produced by thermal shocking alone, the question of reproducibility of the results became important. It was realized that the initiation of a crack and its progress across the edge of a standard specimen would necessarily be a statistical phenomenon. Many random variations, particularly in the local properties of the test specimen, would be bound to show up in the results. In addition, there would be errors in machine operation and personal errors. After considerable effort most of the important machine errors were eliminated by changes in the design. Such developments as the precision water-cooled nozzle and the flexible laminated cantilever type of horizontal specimen mounting materially aided in narrowing the probable-error values of the data. It is felt, however, that the sizes of the samples used in this investigation were too small in many cases. Time limitations prevented obtaining the amount of data required for a good statistical analysis. WADC TR 54-206 31

Fig, 26. HS-21 at 2000~F after 675 Cycles. Fig, 27. Waspalloy at 2000~F after 784 Cyclets WADC TR 54-206 3:2

Investigation into the nature of the thermal-cracking phenomenon was considered and a few photomicrographs were taken of cracks in Inconel and Type 304 stainless steel. These micrographs indicated that the cracks were essentially transgranular in character. Additional, more fundamental, research into the mechanism of thermal cracking is needed, but would be a separate investigation in itself, Recent Work As a result of the first two phases of the program, the investigation narrowed down to the testing of several different materials to determine their relative values of thermal-shock resistance in the absence of any previous mechanical history of axial loading. Four new testing rigs were constructed, tested, and placed in operation. They have operated almost continuously since their completion in December, 19553, and have proven to be very reliable. The primary results of this portion of the investigation are the comparative performancescf the various materials. The average number of thermal-shock cycles to failure for each material is shown in Figs. 28, 29, 30, 31, and 32, for temperatures of 16000, 1700~, 1800~, 1900~, and 2000~F respectively.. The results follow in Tables I-V. Graphical presentations of thermal-shock resistance by classes of materials are given in Figs. 33-37. Tests were also performed to determine the effect of the heating and cooling action on S-816 (wrought) material in the absence of any thermal shock. This was an attempt to find out if the test cycle, by itself, had any influence on the results. It was found that the thermal "wiggling" action alone had no apparent effect on the thermal-shock resistance of the chosen material. Another, rather special, type of test was performed to investigate the effect of corrosion on the rate of crack propogation. It was suspected that after a crack had been initiated, the progress of the crack would be hastened by the development of oxides between the sides of the cracks This would develop a wedging action, spread the crack sides, and cause the head end of the crack to progress, To check this hypothesis, a series of tests were run on Inconel using helium as the coolant in place of compressed air. The shock produced by the helium was visibly more severe than that from the air blast. No significant differences in thermal-shock resistance were revealed by use of the different, inert coolant, although the surface corrosion was considerably reduced. WADC TR 54-206 33

Fig. 28. Comparative Thermal-Shock Resistance Temperature = 1600~F ( ) = Number of Tests 3002 347 SS (5)....l- 3195 INCONEL (BAR B) (2) 3449 INCONEL (BAR C) (3) 4172 S-816 (WROUGHT) (4) 4801 HASTELLOY C (3) 6471 310 SS (I), —----...... 6843 NIMONIC 80-A (2).................... 8511 K152B (I) 8589 N155 (6) _._. _ 11, 682 M-252 (2) 12,048 HS-21 (CAST) (4) 12,549 WASPALLOY (2) OVER 18,000 S-816. CAST) (I) NOTE: BATTELLALLOY NOT TESTED. ESTIMATED OVER 12,000 CYCLES 2 3 4 5 6 7 8 9 10 II 12 AVERAGE THERMAL-SHOCK CYCLES (THOUSANDS) WADC TR 54-206 34

Fig. 29. Comparative Thermal-Shock Resistance Temperature = 1700~F ( ) = Number of Tests 1157 WASPALLOY (4) 1536 INCONEL (BAR C) (3) 1817 S-816 (WROUGHT) (19) 1978 347SS (I) 2250 S-816 (CAST) (2) 2346 INCONEL (BAR B) (9) 2475 K151A (2) 2634 NIMONIC 80-A (3) 2896 N-155 (9) 3072 HASTELLOY C (2) 3789 HS-21 (CAST) (4) 3822 310 SS (3) 8033 M-252 (2) 12,584 HS-21 HEAT-TREATED (4) NOTE: BATTELLALLOY NOT TESTED, ESTIMATED OVER 12,000 CYCLES! l7 I I 1 I I 2 3 4 5 6 7 8 9 10 II 12 AVERAGE THERMAL-SHOCK CYCLES (THOUSANDS) WADC TR 54-206 35

Fig. 30. Comparative Thermal-Shock Resistance Temperature = 1800~F ( )= Number of Tests 391 K152B (I) 653 K151 A (I) 988 S-816 (WROUGHT) (4) 1062 WASPALLOY (3) -- 1286 INCONEL (BAR B) (3) 1357 N-155 (8) 1604 310SS (2) 1704 S-816 (CAST) (3) 2043 HASTELLOY C (3) 2219 M252 (3) 2955 NIMONIC 80-A (3) 3192 HS-21 (CAST) (4) 3752 INCONEL (BARC) (2) 7389 BATTELLALLOY (I) 2 3 4 5 6 7 8 9 10 II 12 AVERAGE THERMAL-SHOCK CYCLES (THOUSANDS) WADC TR 54-206 36

Fig. 31. Comparative Thermal-Shock Resistance Temperature 1900~F ( ) = Number of Tests 469 INCONEL B (4) 1056 WASPALLOY (2) 1069 310 SS (3) - 1097 S-816 (CAST) (3) 1170 S-816 (WROUGHT) (3) 1222 NIMONIC 80-A (2) 1496 N-155 (3) - 1761 M252 (2) 2461 HS-21 (CAST) (2) 3672 HASTELLOY C (2).. - 3850 BATTELLALLOY (2). I.. I I l.L....1...... - - 1 r. 2 3 4 5 6 7 8 9 10 II 12 AVERAGE THERMAL- SHOCK CYCLES (THOUSANDS) WADC TR 54-206 37

Fig. 32. Comparative Thermal- Shock Resistance Temperature = 2000 ~F ( )=Number of Tests 250 K152B (2) 284 K151 A (2) 327 HASTELLOY C (2) 392 INCONEL B (5) 534 H-S-21 CAST (2) 750 310 S.S. (2) 809 NIMONIC 80-A (3) 889 WASPALLOY (3) 891 S-816 (WROUGHT) (4) 1003 S- 816 (CAST) (2) 1278 N-155 (4) 1327 M-252 (2) 3815 BATTELLALLOY (2) III I I I l I, I 0 1 2 3 4 5 6 7 8 9 10 II 12 AVERAGE THERMAL-SHOCK CYCLES ( THOUSANDS) WADC TR 54-206 38

TABLE I THERMAL-SHOCK RESISTANCE AT 1600~F Material Number of Tests Average Thermal-Shock Cycle Battellalloy None Estimated far over 12,000 S-816 (cast) 1 Over 18,000 Waspalloy 2 12,549 HS-21 (cast) 4 12,048 M-252 2 11,682 N-155 6 8,589 K-152 1 8,511 Nimonic 80-A 2 6,843 310 Stainless Steel 1 6,471 Hastelloy C 3 4,801 S-816 (wrought) 4 4,172 Inconel, Bar C 5 3,449 Inconel, Bar B 2 5,195 547 Stainless Steel 5 3,002 TABLE II THERMAL-SHOCK RESISTANCE AT 1700~F Material Number of Tests Average Thermal-Shock Cycle Battellalloy None Estimated far over 12,000 HS-21 (50 hrs, 1350F) 4 12,584 M-252 2 8,033 310 Stainless Steel 3 3,822 HS-21 (cast) 4 3,789 Hastelloy C 2 3,072 N-15.5 9 2,896 Nimonic 80-A 3 2,64 K-151 A 2 2,475 Inconel, Bar B 9 23,46 S-816 (cast) 2 2,250 347 Stainless Steel 1 1,978 S-816 (wrought) 19 1,817 Inconel, Bar C 3 1,536 Waspalloy 4 1,157 WADC TR 54-206 39

TABLE III THERMAL-SHOCK RESISTANCE AT 1800~F Material Number of Tests Average Thermal-Shock Cycles Battellalloy 1 7,839 Inconel, Bar C 2 3,752 HS-21 (cast) 4 3,192 Nimonic 80-A 3 2,955 M-252 3 2,219 Hastelloy C 3 2,043 S-816 (cast) 3 1,704 310 Stainless Steel 2 1,604 N-155 8 1,357 Inconel, Bar B 3 1,286 Waspalloy 3 1,062 S-816 (wrought) 4 988 K-151 A 1 653 K-152 B 1 591 TABLE IV THERMAL-SHOCK RESISTANCE AT 1900~F Material Number of Tests Average Thermal-Shock Cycles Battellalloy 2 3,850 Hastelloy C 2 5,672 HS-21 (cast) 2 2,461 M-252 2 1,761 N-155 3 1,496 Nimonic 80-A 2 1,222 S-816 (wrought) 5 1,170 S-816 (cast) 3 1,097 310 Stainless Steel 3 1,069 Waspalloy 2 1,056 Inconel, Bar B 4 469 WADC TR 54-206 40

TABLE V THERMAL-SHOCK RESISTANCE AT 2000~F Material Number of Tests Average Thermal-Shock Cycles Battellalloy 2 3,815 M-252 2 1,327 N-155 4 1,278 S-816 (cast) 2 1,003 S-816 (wrought) 4 891 Waspalloy 3 889 Nimonic 80-A 3 809 310 Stainless Steel 2 750 HS-21 (cast) 2 534 Inconel, Bar B 5 392 Hastelloy C 2 527 K-151-A 2 284 K-152-B 2 250 WADC TR 54-206 41

WASPALLOY 15 14' Fig. 33. Thermal-Shock Resistance M-252\ 13 M-2 Nickel -Base Alloys January, 1954 12 \; z \ 10 i \ IL\\.o NIMONIC'17 80-A ) ~6-J HASTELLOY \ 5- C\' rNCONEL BAR C HASTLELLOY 1600 1700 1800 1900 2000 TEMPERATURE, OF WADC TR 54-206 42

12 II Fig. 34 Thermal-Shock Resistance 10 Of 0 Iron-Base Alloys o81 January, 1954 lo z 8 \ N-155 7 \ o_1 ~ 310 STAINLESS 6J 4.J 4 347 w 3k 3 3 STAINLESS 21600 1700 1800 1900 2000 TEMPERATURE,F WADC TR 54-206 43

17 16 S-816 (CAST) 15 Fig. 35 14 Thermal - Shock Resistance Cobalt-Base Alloys 13 \ March, 1954 H.S.21 12 D 10 \ o II - 9 \ w \8 I \ \ I[ I0 \t S-816 (WROUGHT) =E 4_ \ I I- 3 2 0 1600 1700 1800 1900 2000 TEMPERATURE, ~F WADC TR 54-206 44

Fig. 36 u | K- 12-B Thermal-Shock Resistance C K-152-B z 10 K-151-A and K-152-B Cermets 3 \ March, 1954 0 9 0 g -- I: W 7 0 WADC T K-151-A \ 3 \ \ I _ 1600 1700 1800 1900 2000 TEMPERATURE, ~F WADC TR 54-206 45

Fig. 37 12 Thermal-Shock Resistance Battellalloy 11 February,1954 u I10 z, 9 IL \ en 7 \ w ~ 6 0 5 Wn 4 IHEAT TREATMENT _~J ~2 hrs at 2200~F Q 3 _ 10 hrs at 1500 OF'2 IL 2 0 1600 1700 1800 1900 2000 TEMPERATURE, OF WADC TR 54-206 46

DISCUSSION OF RESULTS Material Comparison Inspection of the comparative performance charts shows that there is one outstanding material among those tested. This is the special Battellalloy, of which only five specimens were obtained. The first of these was tested at 2000~F in order to get the quickest evaluation. When the thermal-shock resistance proved to be far above that of any other material, a check test at the same temperature was conducted, with similar results. Two more tests were run at 1900~F; the results were comparable to the first two. With only one specimen left, it was decided to run it at 1800~F on the presumption that a test at any lower temperature would take many thousands of cycles to produce any results. Values for the lower temperatures are estimated, Little information as to the physical properties of this alloy is available to account for its remarkable behavior. Of the other materials, only three, M-252, N-155, and S-816 (cast), had a thermalshock resistance of over 1000 cycles when tested at 2000~F. The rest of the materials had values dwindling to 250 cycles for the cermet K-152 B. At 1600~F, the lowest temperature of testing, the materials had thermal-shock resistance ranging from 347 stainless steel, with 3002 cycles, up to S-816 (cast) which lasted more than 18,000 cycles. Two different bars of Inconel, both from the same lot, were tested for comparison of properties within a material. The thermal-shock resistance was nearly the same for tests at 16000F, where bar B had 3195 cycles and bar C withstood 3449 cycles. At 17000F bar C took 1556 cycles wihereas bar B required 2,346 cycles, an increase of almost 53 percent over bar C. At 1800~F the relative merit was reversed, bar C requiring 3752 cycles and bar B needing only 1296 cycles. This represents a difference of about 200 percent with respect to bar B. No comparisons were made for 1900~ and 2000~F. The tests described seem sufficient to demonstrate the large variation in properties to be expected from what is said to be identical material. It would appear, therefore, that thermal-shock tests should involve statistical-sized sample groups if the results are to be reliable. On this basis, most of the tests performed in this investigation are only indications of thermal-shock resistance because of the small size of the sample groups. Thermal-Shock Parameter Correlation There have been several attempts to predict thermal-shock resistance on the basis of physical properties. Manson has proposed two similar parameters, the only difference between them being the omission of the thermal conductivity where the mass of the piece is large in contrast to the cooled portion. It is believed that this situation existed in these tests due to the direction of the coolant over the relatively small edge of the test piece. The parameter may be formulated as or - Ea ca WADC TR 54-206 47

where a is the ultimate strength of the material, E is the elastic modulus, a is the thermal-expansion coefficient, and E is the strain at the ultimate stress. Usually the first form is used because of the difficulty of measuring e. The correlation of the observed thermal-shock resistance with the Manson criteria was so poor it was of little value. The primary use of these thermalshock resistance criteria has been on brittle materials, where single thermalshock cycles can be made to produce failure; in the present investigation no such materials were examined. Also,a considerable portion of the discrepancy may lie in the obtainable values for the physical properties involved. Most tensile-test data are given for room-temperature conditions, or for temperatures up to about 12000F. Thermal expansivities are usually given for ranges of values which are considerably removed from the test conditions, Further, it is known that all the terms in the parameter are variable with temperature. Until accurate values can be obtained for the quantities involved, any correlation with the proposed parameter will be doubtful. Effects of Temperature On all materials the raising of the test temperature lowered the thermal-shock resistance. In some materials, such as Waspalloy and S-816 (cast), this loss of resistance was very severe above 1600~F. In other materials the loss was more gradual, but they all tended to a smaller and smaller value with rising temperature. The reasons for this behavior may be found in the mechanical and metallurgical changes which take place in the materials at high temperatures. For most materials the coefficient of thermal expansion increases with higher temperatures, while the breaking strength decreases. Thus, it would appear that a given thermal quench would affect a relatively larger proportion of the breaking strength when applied at high temperatures than when applied at lower ones. Several such quenches would do a proportionately larger amount of damage to the specimen at the higher temperatures, For some materials the higher temperatures resulted in actual softening to the point where the specimen sagged out of shape. In less drastic cases there was considerable upsetting on the hot(compression) side of the test piece, also indicating plastic action. Such plastic action undoubtedly helped in relaxing the thermal stresses induced by the quenching, but rapid failures were commonly produced. At temperatures of 19000 and 2000~F materials such as the stainless steels and Inconel were very badly oxidized and were subject to severe pitting, erosion, and surface scaling. As a check to see what effect these conditions might have on thermalshock resistance, tests were run on Hastelloy C and Inconel usi-ng a helium coolantinstead of compressed air, While the surface corrosion was reduced the thermal-shock resistance was not appreciable affected by this change in test conditions. (See Figs. 38 and 39.) In several types of materials it is possible that certain metallurgical changes would also take place at the temperatures involved. These changes would fall into the categories of aging, hot-working, and grain growth, No metallographical examinations were made of the specimens after testing because of time and financial limitations. It may be pointed out that future investigations should include such examinations in their program, WADC TR 54-206 48

...........0~~~~~~~~~~~~~~~~:: E'1.R. 78, Kasl~~~~~~~~~~~~~~~~~~~~~el~~~~~loy C Ri; 20000F, nir-Cooled~~~~~~~~~~~~~~~~~~~~~~~~~~~....... For 291. ffyca~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~e ~ ~ ~ ~ ~ ~ ~..... Flig. Ha~dtstelloyc r C at 20000FI, Air-Ctn-ooledi f or 291r Cyclies. fi~~~~~~~~~~~~fh~~~~~~~~~~~~d~~~~~~~~f: CXTS~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~~~~~~~tb-20~~~~~~~~~~~~~~~~~~~~~~ 49..........

Type of Crack During this investigation there were no instances of cracking from a single thermal shock, in contrast to some reported tests on ceramic materials. This indicates that thermal-shock cracking was a progressive phenomenon for the materials tested, and shows that the action was one of thermal fatigue. On most specimens the crack or cracks were first visible under a 5X eyepiece as small hairlines at the top or bottom of the edge being shocked. Under continued shocking the cracks grew in length until they had crossed the edge, at which time failure was said to have taken place. Usually the rate of crack development was a very irregular thing, but a fortuitous set of observations on the one specimen of N-155 at 1600~F showed a rather uniform crack development at a rate of 0.0001 inch per cycle, after initiation of the crack at 6574 cycles. Except for HS-21 and the Kennametals, this cracking rate is thought to be of the right order of magnitude for the other materials. HS-21 cracked at a higher rate than this once a crack was started, The Kennametals exhibited very rapid crack progression; in one case the specimen cracked completely into two pieces within 20 cycles, whereas the usual test involves the development of a crack only about 0.040 inch long, CONCLUSIONS 1. In the usual metallic materials intended for high-temperature service, thermalshock cracking is produced by thermal fatigue except for shapes of greatly varying section. 2, Thermal fatigue is a cumulative process which continues until a crack is initiated; then the failure process becomes a combination of fatigue effects and stressconcentration effects. 5. The order of decreasing resistance to thermal shock at the test temperatures was as shown in Table VI. 4. Correlation of thermal-shock resistance with the e/a criterion was poor, but the available data on which it is based is considered of doubtful value. 5. Large variations of thermal-shock resistance occur within a given material. For reliable results a statistical-sized sample group must be used. 6. Increasing the temperature lowers the thermal-shock resistance of the materials tested. 7. Mechanical fatiguing of type 347 stainless steel prior to thermal-shock testing resulted in a decrease in the sensitivity of this material to variations in edge width, and a decrease in the width of the scatter band of the data. 8. Mechanical cold stretching of 1, 5, and 10 percent prior to thermal-shock testing of Inconel developed no significant change in the thermal-shock resistance of this material. WADC TR 54-206 50

9. Thermal heating and cooling without thermal shock has a negligible effect on the thermal-shock resistance of S-816 (wrought) at 1700~F. 10. Coolant tests on Inconel at 2000~F showed little difference in thermal-shock resistance between helium or air coolant. TABLE VI DECREASING ORDER OF THERMAL-SHOCK RESISTANCE 2000~F 1900~F 1800~F 17000F 1600~F Battellalloy Battellalloy Battellalloy Battellalloy Battellalloy M-252 Hastelloy C HS-21 (cast) HS-21 heat- S-816 (cast) treated N-155 HS-21 (cast Nimonic 80-A M-252 Waspalloy S-816 (cast) M-252 Inconel 310 stainless HS-21 (cast) steel S-816 (wrought) N-155 M-252 HS-21 (cast) M-252 Waspalloy Nimonic 80-A Hastelloy C Hastelloy C N-155 Nimonic 80-A S-816 (wrought) S-816 (cast) N-155 K-152 B 310 stainless S-816 (cast) 310 stainless Nimonic 80-A Nimonic 80-A steel steel HS-21 (cast) 310 stainless N-155 K-151 A 310 stainless steel steel Inconel Waspalloy Waspalloy S-816 (cast) Hastelloy C Hastelloy C Inconel S-816 (wrought) Inconel S-816 (wrought) K-151 A K-151 A 347 stainless Inconel steel K-152 B K-152 B S-816 (wrought) 347 stainless steel Waspalloy WADC TR 54-206 51

BIBLIOGRAPHY 1. Norton, F H., Refractories, McGraw-Hill Book Company, 2nd ed., 1942. 2. Lidman, W. G., and Bobrowsky, A. R., "Correlation of the Physical Properties of Ceramic Materials with Resistance to Fracture by Thermal Shock", N.A.C.A. TN 1918, 1949. 5. Whitman, M. J., Hall, R. W., and Yaker, C., "Resistance of Six Cast High-Temperature Alloys to Cracking by Thermal Shock", N.A.C.A. TN 2037, 1950* 4. Avery, Howard S., and Matthews, Norman A., "Cast Heat-Resistant Alloys of the 16% Chromium-355 Nickel Type", Trans. A.S.M. 58, 957 (1947). 5i Manson, S. S., "Behavior of Materials under Conditions of Thermal Stress", N.A.C.A. TN 2933, July, 1953. 6. Hoffman, C A., and Cooper, A. L., "Investigation of Titanium Carbide Base Ceramals Containing Either Nickel or Cobalt Base for Use as Gas Turbine Blades", N.A.C.A., RM E 52 H05, 1952. 7. Crandall, W. B., "Evaluation Techniques for High Temperature Metal-Ceramic Materials" Paper 30, WADC TR 52-127, 1952. 8. Baker, N. I., "Recent Thermal Shock Testing Results", Progress Report for N.A.C.A. Subcommittee on Heat Resistant Materials, Edited by W. L. Badger, General Electric Company, Thompson Laboratories, 1953. 9. Cooper, A. L., and Colteryahn, L. E., "Elevated Temperature Properties of Titanium Carbide Base Ceramals Containing Nickel and Iron", N.A.C.A., RM E 51 I10, 1951. WADC TR 54-206 52

APPENDIX WADC TR 54-206

(A3 0 0N ~F- C, - _^~ 1-^ — ( -- --,4\ U.'^g —-— ^0 -J ( VI 3 I 0j 0 0 ~ 01' -- @ _ —----------------- ---- I ~ ^~r ^-' s ^ ^O0~a ^0 ^^ ^ ^? >?~~~~~~~~~,-^ -^, —--— ^s -----— ^,r WAC TR5-265

KEY TO WIRING SCHEMATIC Q DPDT 115V 60" Relay (Potter and Brumfield MR1lA) DPDT ll11 60f Relay (Potter and Brumfield MRllA) DPDT 115V 60" Relay (Potter and Brumfield PR11A) DPDT ll5v 60" Relay (Potter and Brumfield MRllA) (Q SPDT 115V 60o Relay (Potter and Brumfield PR5A) F 20-see Thermal Time-delay Relay (Amperite 115N020) () DPDT 230V 60" Relay (Potter and Brumfield MRllA) )PL Neon Pilot Light 115v [w Wheelco 241-P Capacitrol'IJ Running Time Meter (GE 8KT9D2) IJC Counter (Veeder.Root B120506) ISVI Solenoid Valve (Detroit Lubricator No. 681)'TAI Timer, 2 min (GE 3TSA10 AF9) ITBi Timers 30sec (GE 5TSA10 AF5) Si NO, Push Button S2 N.C. Push Button S3 4 Pole 2 Pos. Rotary Switch (Mallory 3242J) 0 3 0411O10k 2350VAC d HIeinemann Circuit-breaker Switch: l: Po0411-, 15 VAC 4; $ P041-^ 115f Normally closed contacts Normally open contacts Cut-off Selector Switch; shown in Temp position on schematic (Beginning of cooling portion of' cycle controlled by Wheelco Capacitrol) In Time position, beginning of cooling controlled by TA (0-2 min) WADC TR 54-206 55

COMPOEINT PARTS OF THERMAL-SHOCK APPARATUS Quantity Unit Component Parts (per unit) Quantity Namne 2 Dual Test Stand 2 Specimen Holder Assemblyt 2 Air Nozzlet 2 Wheelco A0429 Heat Eye* 2 Heat Eye Support 2 Power Transformer 2 Det.. Lub, No, 681 Solenoid Valve* 2 4-cu-ft Air Tank 1 Steel Tablet 4 Control Unit 1 ICA/3912 Relay Rack 1 ICA/3601RS Panel, 3-1/2 x 19 1 ICA/3605RS Panel., 8-3/4 x 19 2 ICA/3605RS Panel, 10-1/2 x 19 1 ICA/3606RS Panel, 12-1/4 x 19 1 ICA/3607 Panel, 14 x 19 1 ICA/3654RS Panel, 3-Metersy 5-1/4 x 19 1 ICA/4031 Chassis, 13 x 17 x 4 1 ICA/4070 Bottom Plate 15 x 17 1 Wheelco 241-P Capacitrol 1 V-R B120506 Magnetic Counter 1 Simpson Mod 57 Voltmeter, 0-300v 1 Simpson Mod 57 Ammeter, 0-10a 1 GE. 8KT803 Time Meter 1/10 hr 1 GR, V20HM Variac 1 GE, 3TSA10AF5 Timer 30 sec 1. G.E, 3TSA10AF9 Timer 2 min 2 Heinemann P0411-4 Circuit Breaker 2 Heinemann 0411-10 Circuit Breaker 1 Potter and Brumfield PR5A Relay 115v 1 Potter and Brumfield PRllA Relay 115v 3 Potter and Brumfield MRllA Relay 115v 1 Potter and Brumfield MRllA Relay 230V 1 Amperite 115N020 Relay 115V 4 Pilot light, assem, 115V 2 Push button switch 14001 NO 1-4002 NC 1 Mallory 3242J 4PDT Switch __- _Wire, plugs, receptacles and hardware tFabricated locally *Purchased IBuilt per our specifications by Osborne Transformer Corp., Detroit, Mich,(Type No,22584) WADC TR 54-206 56

NISCLLANEOUS CAPITAI ITEMS Not Physieal Parts of Above Unita Quantity Name 1 Mercoid DA31 Pressure Control 1 Allen Bradley BA22 Contactor.~'Wire, cablebs plugs and receptacles to connect Control Units to Test Stands POWER TRANSFORMER SpecifiCat ion Primary: 140 T,. [No, 8 AWG Copper] Secondary: 1 Tu [12 pCes.o020 x 4 Copper SheetI in parallel] Leads: Primary; No. 8 stranded Secondary; 2 1/4 x 2 Copper bar in parallel Core: Shell.Type, 4% Si, Cross-.:section 12,5 in2 (Or equivalent grain.oriented. spiral core) Construction: Open (core and coil) Dimeni.ons: 9 in, wide x 9-1/4 in., high x 7 in, deep (overall) 3uilt by: Osborae Tranaformer Corporation, Detroit, Michigan Type'No 22384 Rating: 1920 V*A. WADC TR 54-206 5

KEY TO LOG Column (1) (1) Relative psition on bar stock 1 Spec.imen number ColuM. (2) Arrow indicates direction and location of cooling jet; cooling medium is air unless otherwise stated W Cooling medium is water o045 Width of ~cooleededge inches P.F*. Previously subjeeted to rotating beam fatigue as shown in column (6) X Failed during pre-fatigue 1700/5 Nmber in parentheses indicates average of calibrations at beginning and (1718) end of test (Mean max test temp) Coliumn (3) M Therl shock eycle nually controlled 1500/5 Autcamatic eycle control; maxinu temperature,'F, and length of cooling period, se:onds P1800 Dead load, 1800 Ibs +10/100 Starting with stated maximm temperature, raximum temperature was increased 10F after each 100 cycles )40.5K ReverSed-bending (rotating.'beam) fatigue tests; maximnm stress, 400500 psi to 1800 Maximum temperature held constant after 1800F was reached Column (4) A Air co'oling for stated number of cycles W Water coaling for Stated number of cycles no symbol Air cooling for stated number of.ycles Colrtn (5) 0 No failure visible F Fracture C Cracks G Grooves FC Face crack PC Possible crack Column (6) B Specimen warped due to thermal strains A 0o14 Area of cross section, square inch T300/1600 Ieat treated before testing 500 hr at 16000F G15 t appeared at 1500 Groves firt appeared yat 1500 cycles OH Stated maxiJm m tem'perature was exceeded due to.malfanetion of control mnit BT Broke through to thermocouple hole WADC TR 54-206 58

pf 700/60 Previosly subjected to eyclic heating and cooling I1200/23 (M temp) 1700/60 (heating time, seconds) (Min temp) 1200/2 (Cooling time, seconds) (Number of cycles) 1000 4 /000'Previously subjected to 82000 cycles at 40J500 psi 82000 R Reproducibility test N Specimen foredd a neck due to tensile strain +100/5108 Maximt temperature was increased l00F at 5108 cycles Cheek II Second test to determine the effect of alteration of testing procedre P Study of crack propagation PT1 Previously subjeeted to tensile strain of 1% at room temperature LRS1 LongI-time test at reduced severity, Test No, 1 Tt}l Heat treated as shown in braces [ ), Lot No. I C20/1700 Heat treated for 20 hours by heating to 1700'F and allowing to cool for 5 seconds by natural conveetion Column (2) Letter at tail of arrow indlcates test unit on whih test was run. Two arrows indicate two separate tests with cooling on different edges, Horizontal arrow indicates first test Column (3) Nuamber [e.g, (1)] indicates edge namber, shown in Column. (2), on which test was run WADC TR 54-206 59

TEST LOG Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Type 304 Stainless Steel /045 M 0 B 2 \ 1600/10 4400A 0 B 300W C 3 \0/ l6oo/4 1783 C V +o10/100 4a Fatigue 40.5K 3300 F 4b SpeC.imaens 40.5K 2600 F 5 O/ 01700/4 1100 0.k 1800/4 675 C 6 7 1600/4 6240 0 G6500 1900/4.1240 C 7 K 7 1500/5 4150 F Ao.16 ~~V ~ P600 8 \ a1600/5 5082 0 T o00/1600 1800/4 517 c WADC TR 54-206

TEST LOG (cont,) Specimen Gross Number Type of Number' Section Cycle of Cycles Failure Remarks (1) (2) (5) (4) (5) (6) Type 504 Stainless Steel (ciant_ 9 \7 15oo00/ 5753 0 1600/4 1000 0 1o \ / 1700/4 1000 0 1800/4 80 C 11 1500/5 1000 F AO.132 P1800 1500oo/5 12 2~P600 5200 0 A0.155 P900 1200 0 P1800 203 F' 153 0 1600/4 1284 C G1115 14 1500/4 1000 F OH 15 \ 1600/5 190,0 C T 300/1600 16. _ 1600/5 409 C WADC TR 54-206 61

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) ____ (2) (3) (4) (5) (6) Type'04 Stainless Steel (cont.) 17 1500/5 300 F A0.l140 P1800 18 1800/4 1950 C G1500 19 1700/53 530 C 20 1500/5 1000 0 BT Type 310 Stainless Steel B9-1 \7 1900/5 1024 C T 2/2100 o40 V - (1907) B9-2 \77 1900/5 1008 C T 2/ao00 041 V<- (1907) B9-3 1900/5 1177 C T 2/2100 0 V9 - (1885) B9-4 \ 72000/5 707 0 T 2/2100 o58 v. (1990) WADC TR 54-206 62

TEST LOG (cont.) Specimeen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Type 310 Stainless Steel (cont:).. B9-5 2000/5 794 C T 2/2100 04, 2 V - (2012) B9-6 1800/5 1873 C T 2/2100 B9-T..7 1800/5 1435 C T 2/2100 044 V<- (1810) B9-8 7 1700/5 2770 C T 2/2100 044 - (1720) B9-9 1700/5 3500 C T 2/2100 B9-10 \ 5197 C T 2/2100 O42 V4- (1692.). B9-11 1600/5 6471 C T 2/2100 040oV< (1583) Type 347 Stainless Steel 1 \0/ 1600/4 866 C ~Vo45 +10/100 WADC TR 54-206 6

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Type 347 Stainless Steel 2 \0/ 600/4 1147 C 02 +10/100 5 <~79> 1500/4 575 C B.T. +10/100 4a Fatigue 54K 5200 F 41b Specimens 54K 10400 F 40. K/ 82000 5 \~/1500/4 1326 C +10/100 6 1500/4 1990 C = VI ~ +10/100 (74\ ~1600/4 7 ~ VjI +10/100 2700 G to 1800 8 (Defective) Used for bend test 9 \0/ 1600/4 2865 C R 64 WADC TR 54-206

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (_) (.____(2) (3) (4) (5) (6) Type 347 Stainless Steel 10 \~/ 1600/4 3787 C Check II -~ 020 11 _7 1600/4 2580 C -^v 050 12 0/ 1600/4 3162 C G736 -+v 020 153 \ / 1600/4 2204 C G2072 —' v020 14 1600/4 2707 C G2604 020 15 0 1600/4 3005 C G2820 055 R 16 \7 / 1600/4 2518 C R 020 17 \ / 1600/4 4850 0 Check I V 023 WADC TR 54-206 6

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Type 347 Stainless Steel(cont,) 18 / Fatigue 7200 F 54K V 64K 103300 19 1600/4 1825 C R V 35 37K/217100 42K/11000 20 / Fatigue 4300 F 48K/35600 64K 54K/10000 59K/10400 21 1600/4 4430 C 22 -> 1 1 1600/5 1423 C T 2/2000 108 23 1600/5 2962 C 24' / Fatigue 52900 F V 010 59K 25 / 1600/5 1562 C 54K/50000 -V 010 PF WADC TR 54-206 66

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (l) (2) (3) (4) (5) (6) Type 347 Stainless Steel(cont,) 53K/52000 59K/12000 26 \0/ 1600/5 1960 C 64K/1000 _V Ol10 PF 70K/1000 __________________________________75K/5 00 27 7Vj x F 55K/52000 010 P 59K/11300 55K/52000 59K/12000 28 \0/ 1600/5 1594 C 64K/1000 010 PF 70K/1000 75K/500 553K/52000 59K/12000 29 x C 64K/1000oo V 010 PF 70K/1000 ____~ ~___ __ _ _ ^__________________75K/300 50'07 1600/5 1.975 C -iV 01.0 51 7 / 1600/5 2764 C —._> 010 52 1600/5 1500 C -/010 535 x F 59K/52600 (4) V o P WADC TR 54-206

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Type 347 Stainless Steel {(cont,) 34 \ / 1600/5 1811 C 60K/59000 (3) 36 PF 35 V/ Useec for Calibration of Heat Eye (2) 36 \0/ 1600/5 1859 C 58K/30000 (l) ~v o4o PF 37 \7 / 1600/5 4635 C (5) jlV o040 38 1600/5 2114 C T 2/2000 025 39 \ 1.600/5 2440 G G2440 (7) 050V40 1600/5 3143 G _V_ o25 41 10/ 600/5 2710 C G2000 68 WADC TR 54-206

TEST LOG (cont,) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (l)_) _(2) (3) (4) (5) (6) Type 347 Stainles's Steei (cont~) 42 U\ / Used for Calibration 4I-73 1600/5 10708 C P (11) 025V<44 708 1600/5 2046 C T2/2000 (12) 055 <45 1600/5 1956 C T2/2000 (153) AS*, 21 1? 7 1500/355 1000 C BT +10/100 2 \ 7 1700/5 3552 C 0465 (1718) 53 ~0 \ 71900/5 2625 C 045 V- <(1917) 4 7 /O17 00/5 6820 C FC 6003 049 (1719).4C 6561 WADC TR 54-206 69

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) 5,?s. 2l(cont). 5 \ / 7, 1800/5 1252 C 045 V 6 1900/5 2309 C 03, (1862 7 1700/5 1506 C.o485 V. (1720) 8 \ 1800/5 3468 C 047 9 1600/5 5305 C 05757 i- (1605) 10 77J7 2000/5 675 C 11 \7 1600/5 17615 C 0435V< (16o5) 12 777 1700/5 7575 C 51/1550 WADC TR 54-206 70

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) ______(2) (3) (4)(_ (6) H.,S.:21 (cont) 15 3 1800/5 3902 C 0435 V - ll4 Used for Fatigue Specimen 15 1600/5 15334 0 16 1700/5 14489 C T 51/1350 17 \ / 1700/5 3279 C 0395 (1708) FC'00o4 18 2000/5 396 C 0538 V (1990) 19 1700/5 10060 C T 51/1550 051 20 1800/5 4147 - C 05D9 VR 5- 0 1 WADC TI 54-206 71

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles. Failure Remarks (1) (2) (5) (4) (5) (6) H.S, 21 (cont,) 21 1600/5 9958 C 0355 V (1613) 22 \0/ 1700/5 18411 C T'51/1350 Inconel 1 \/ 1500/3 1450 C G1150 015 +10/100 2 7 7/ 1500/3 2750 C 3050 +10/100 o 1500/3-1/2 428 C 055 4 \ / 1700/5 35167 C 2/500 0355 T 1/3/1400 5.V/ 1700/5 1819 C 2/500 055V T L/3/1400 6 1600/4 7449 C 055 WADC TR 54-206 72

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Inconel (cont*).... 7 \o 1700/5 4706 C 2/500 055 T^ 1//3/1oo 8 o/ 1700/5 2090 C T 1/3/14oo 025V — PT 1 9 \~/ 1700/5 6465 C 2/800 - 025 T 1/3/1400 10 1700/5 3685 C T 1/3/1400 055 v- PT 10 11 1700/5 2860 C T 1/3/1400 028v PT 5 12 7 1700/5 1884 C 1/3/1400 030v.. T/20/1700 153 \ 1700/5 2500 C T 1/3/1400 025 PT 1 14 \/ 1700/5 2527 C T 1/3/1400 050VT 54-0PT 5 WADC TR 54-206

,ST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (4) (5) (6) Inconel 15 \o/ 1700/5 2804 C T.'1/3/1400 030\ / PT 10 16 / 1700/5 590 C T 1/5/1400 025 V17 1700/5 2270 c T:'1/3/1400 030 Vf_- PT 1 18 Vy 1700/5 5015 C T. 1/3/1400 051"< PT 5' o-7 T 1/5/1400 19 1700/5 1830 C PT 10 025 20 \oo 1700/5 2898 C T 1/5/1400 21 ~~ ~~~~~~~~\ ~/ T'1/5/1400 21 O' " 1700/5 7498 FC? LRSI — Vo030o 11265 C Y —7, \0/~~~~~~~ T 1/5/1400 22 1700/5 4339 FC? (RS) a/c 0553V- 6866 C Flex. pipe to nozzle WADC TR 54-206 74

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1 )____) (2 ) _ (3 ) (4 ) ( )) (6 ) Inconel (cont.) 25 1700/5 2250 C T 1/5/1400 055 V 24 1700/5 8145 C T 1/5/1400 — Vo50 LRS II -030 25 1700/5 5558 FC T 1/5/1400 o35q^v ~- 4229 C Inconel Lot II C-l 1600/5 4558- C T 1/3/1400 o55V/ 0-2.1600/5 3416- C T 1/5/1400 056 v, C-3 1600/5 2572- C T 1/3/1400 041 C-4 1700/5 1695+ C 0.9 T 1/3/1400 1700/5 178/3/1 oh4oV-7 WADC TR 54-,206 75

TEST LOG (cont,) Specimen.Cross Number Type Of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (5) (6) Inconel Lot II C-6 \7 1700/5 1537 C T 1/35/1400 045y^ C-7 777 1800/5 5854' C T 1/5/1400 042 V- (1845) C.-8 1800/5 3204 C rT 1/3/1400 06 (1790) 3651 3C Spec. upset 2000/5 752 0 in middle011. (1998) shorteiened''.............__________1_ me.....................1/4 inch Tl//140 Air removes C-10 2000/5 752 0 scale from 3905S - (1950) cooled area Inconel tot II (1/2-inch Diameter Rod). 4\-7047 B-1 1700/5 2267 C 045 1700/5 1760 C.. —'040 B-2 1700/5 2544 C 037 v- 1700/5 2527 C B-3 1700oo/5 2622 C o47T- WADC TR 54-206 76

TEST LOG (cont,) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1)(2) (3) (4) (5)(6 Inconel Lot II (l/2-i'nth Diaieter Rod.) coIt') B.-4 2000/5 958- C 04 B-5 2000/5 598 C 039 V^ B-6 \7 2000/5 212 C 045 - -77 o000/5 40o? C 0465 Vi'. 299 B-8 \0 / 1700/5 2560 C 044 V'B-9 1700/5 2283 C 040 V —70 B-10\o 1700/5 2206 C 058 V-. - B-l Not Used 042 VR 6 WADC TR 54-206 77

TEST LOG (cont,) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (Lz___) )(2) (3) (4) (~)(6) Inconel Lot II,1/2-inch Diameter Rod) cont.)'. B-12 2 o000/5 110? C 04 143 B-1 3 1900/5 580 042 B-14 1900/5 463 044 - B-15 1900/5 659 C B-16 1900/5 175 B-17 1800/5 480 18 18/ 1962 C B-18 1800/5 51962 C 046 V<WADC TR 54-206 78

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (a.) (2) (3) (4) (5) (6) S-816 Alloy (Wrought) N 1 7/ 1500/4 1788 0 +100/5108 P700 18391 C +100/10000 No load Y~7 ~ 1500/4 2 P1100 2657 F A o008 to N P700 3 \0/ 1700/4 2256 C,~V 020 4 \7 1700/4 2550 C " 020 i5- \o/ 1600/4 3870 C 6 \0/ 1500/4 26530 C - 023 7 1500/4 15280 C 27V 025 8 DV/ 1600/4 7497 C WADC TR 594206 79

TEST LOG (contP.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (z) (2) (3) (4) (.5) (6) S-816 Alloy (Wrought) (eont,) g9 \ /1800/5 lo69 0 TCJ4it ooI 03 (1805) 10 1700/5 2426 C T 11/218503 037 (1700) 16/1800 11 16oo00/5 510 C 1l1/1800 0356 Vf- (1606) 1l6/18o00 12 77 1800/5 956" C T1/25W 0388 V (1797) [16/1800._* ---—....... --. *.... -, -___ ^_^^-.,,~i uI, ~, ij 1. MI,,, H —- *; *; r -, * L ~-~- J I-~-~-I.'" -'.' ". -'..':. " —... -'- *-'.. 15 \ 1700/5 19053+ C Tj21/0W (1705) (000o short) (003 short). 14 7 1800/5 1146T 1/2150W) 1800/5 1146-. -C 16/10 15 777 1600/4 4600 C T 1/6/1800W 06 (161) 1 16 5/ o/ 5620 C T 1/215W') 0555 o (D7 [160/ 6/:18oo 0 WADC TR 54-206 80

TEST LOG (cont.) Spec iien Cross Number Type of Number Section Cycle of Cycles. Failure Remarks (i_) )(2 )_ (_) (4 ) (_) (6) S8l66 Alloy (Wrought) (cont.) 17 71 1700/5 1956' C T. l/21504I 0562 (1715) 16/l8oo0 18 1800/5 784 C Tfl/21l0wI 04 (i ) z16/1800J 0384 (1790) 19 1700/5 2500" C rT1/215OW I 03 (1713) 16/1800 20 77 1600/5 3500' C T I0W3o - 16/1800JII 21 \/ 00/9 2190 01600 22 \/1700/5 72190 C PfQ 6Oy 055o. (1692) 5 8200 N J i16 1/800i 25 1700/5 1414 C P /17 _/60 03 55V (1695) 1200 24 1700/5 1697 C P 01700 60 0585...- (16.98).....' __1040 N I WADC TR 5L4-206 81 ~ ~ ~ ~ o o / ~ ~ ~ ~ o ~ P ( ~ 7.~112~ ~I' e

TEST LOG (cont,) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarlsm (1) (2 ) (:____( )___ (3 ) (4 ) C( ) (6 ) S-816 Alloy (Wrought) (cont*) 25 777 1700/5 2328 C T/21.5 I 0540 V<- (1702) 1:6/1800) 26 1700/5 2239 c T/: L 800.,.. 0 o. (1-.715) 116/1800 27 1700/6 1967 C T 1/21.00o 3" 0U K. (1690) "16/1800 28 7 1700/5 1598 C L II 0357 (1705)16/1800 (6/1800 ~ J 29 1700/5 1122 C p'00: /6_ 051V (17)695P)1/100695) (2000 X (2000 N ) 0352 < (1670) (17 /60J 12000 W J 31 1700/5 52 C 03 V. (1702) Pl P 200o 23 000.6/.ooj WADC TR 54-20.6 82

TEST LOG (co.-t,) Specie'aEn Cross Number Type of Number Section Cycle of Cycles Failure Remarks (a.) (2) (5) (4) (5) (6) s:-816 Alloy (Wrought),. (c,, t T/2150 I 3355 100/5 1700 C 0577 (1715) pl7O/60 \4- ^1200/ 23.3121 N 54 p/1700/5 1545 Cf,/6o~ Tf1/2150 ) V" ~~~~T~~~~~7 UT16/1800J 034 V1 792oo/i S->816 AllOy (Wro.ught) Lot II P6-i 7 1900/5 1082 Q T 21^50] P6-2 777 1900/5 1551 C T 616/18500 P6-3 7 1900/5 1077 C T Z| 0158 Ve-' 1 0 P6 —4 2000/5 786 C T.{/o2150 P6-.5 \2000/5 1071 C T 6/100l0 WADC TR 54-206 85

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (]_ __) i(2) (3) (4) ()(6) S-816 Alloy (Wrought) Lot II (cont.y) P6-6 2oo 2000/5 800 C T P6-7 P6-8 \7 2000/5 976 C Tf/ 50 0)i9 2000/5 16/1800f 049. _-.. s-816 (Cast)_ 6-1 \ / 1800/5 1557 C 047 V< (1805) 6-2 1800/5 3005 C 038v- (1840?) 67-3 1900/5 1522 C 057 Vf- (1880) 6-.4 7 1800/5 54'9 C 0o8 V ^- (1805) WADC TR 54-206 84

TEST LOG (cont.) Specimen Cross Number Type of Number Seetion Cycle of Cycles Failure Renmarks (z) (2) (3) (4).6) s-816 (Oast) (con-t;)......... 6-V5 1900/5 1040 C 053 (1927) 6 —6 Used for Fatigue Specimens 6-\7 1900/5 729 C 039 ve 6-8 2000/5 1370 C 041L v(- (1982) 6-9 \7 2000/5 636 C 05 (2017) 6-10 17oo/5 2090 C 07 (1717) 6-11 1700/5 2509 C 06 vf- (1710) 6-12 777 1600/5 18700 0 No Cracki 035 vsto- p s'pe. WADC TR 54-206 85

TEST LOG (eonto) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) ___ (2) __ (53) ~4) (5) (.6) N-155 Alloy (Wrought) 376.4 PC /3/220OW 1 700/5 3878 C T/.(1) T 038 4949 20C 2 1700/5 3211 C T{o/.2oo0..?. 1 040 (50740 3 1700/5 35248 C T1/5/2200/ i 038 50/1400 05.1800/5 1508 C T'3/200W -038. 0/3/2200oW) 150/1400 f 5 1600/5 5886 0 Removed 11-15 036 for check-.no crack 6 1700/5 3105 C T1 7 1800/5 1818 C / 0 J 042.50/is I 8 1700/5 5195 C T|Ioo//22/f WADC TR 54.-206 86

TEST LOG (cont.) Spec imen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3) (_) (5) (6) N3155 Alloy (Wrought) _ 9 ^ \1700/5 2888 c o/o o1 10 \J1600/5 10124 0 TT1/3/220OW I 05 50/1400 | 12 1800/5 1228 C T l/3/2200Wj> 018 150/1400 14 71800/5 1042 C T l/5/2200WII T0354 Vo50/1400 f — 15 \1800/5 990 C T(1/3/22. O I, 0415 V^-o (50/1400 j WADC TR 54-206 87

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (3)_ ('_4) ( )_) _3(6) N.155 Alloy (Wrought). (.ont.):, 17 1700/5 2229 C T./3/ Tf/55/1400 18 1700/5 1995 C T o/2200W] II 1..?9 1600/5 5153 C r/3/22.o.:,..6oo50/1400 22 0 \7J7 1600/5 7000 c T^ 035 ~252 \" 1600/5 T6728 C Tl /220W 11I W6ADCT T850/1400 wc TR 4-206 88

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failuxe IRemarks (1.)____ (2>) __ (3) (4) (5)(6) NS155 Alloy (WrouLght) Lot II C5-1 2000/5 1287- c T l/j/220 049LV - J50/140O J 2 2000/5 1083 C T L/3/20 o4o - / 50/1400 05-3 \ /2000/5 i9775 C T /5/2200o c.5-4\o 2000/5 966 C 2)/3.8C T 00 o46 4- (50/1400 C5-5 1900/5 14 C T /2200 50 11400 05-6 o1900/5 1z8 C T C5-8 1600/5 19000 0 Tf.o3/2200 039 V Lo/1i.4oo WADC TR 54-206 89

TEST LOG (cont,) Specimen Cross Number Type of Number Section Cycle of Cycles Failure: Remarks (z) ___(_(2) (3) (4) (5) (6) waspalloy A5l 777 1600/5 10050 c ~T 16/140j A3-1 o/ o16/140oo 7775 \1800/51789" C Tr4/1975.. /-oo(1798)6i.00 A35.-2\ 1600/5 15048 C T16/1400 04'~ -(1005)16/1400: A5-5 1800703(1'798) C T'4' A53-4 1800/5 613 c T/ 0o4 (1795) 4/1975 A3- 1700/5 879 C T 16/1400 39 542(16906) o... (:1.705)

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1)_ ___(2) (3) (4) (5) (6) Waspalloy (cont.)) A3-9 1650/5 1690 C T'l/L97o 04 (i68o) A3L0 970/5 1102 C T4/'97 0 (:880) A53-11 1900/5 1010 C T 64O 039 Y (1920).. ^ ^, -. ^, *, I::....-...........'... 1........................;................. A3-12 200o/5 784 C T 1Ig/97. o 5 (2002) A-5 3 2000/5 622 C T i975 042 v (1990) A3-14 2000/5 1263' C T 4/19750 0o 45V.-. over (ll..16/1400) A5-15 1tt Usied A5-16 2000/5 1265 C 0 V (1982) er WADC TR 54-206 91

TEST LOG (cont.) Speeimt n Cross Number -Type of Number Section Cycle of Cycles Failure Remarks (1___) )(2) ___ (3)__ _ (4>)__ (53(6). M.-22 Alloy: B2. -1 \ 160o0/ 1648.5/13964 5/1"950 ( 04 (1575) 1ix 5/l400o v l>~ ~ oo/~~ C 4/1950 B2*2 1600/5 7717.2 over T 045 - (1595).1 over 15/140 B2M o 1700/ 3747 C T 10'04,7 V<^- (1745?) [ 5/1400J B2-4 1700/5 12318 C T /195o7 04 (1.690) 15/1400 04^-4i lgcr/5 27(4/1950? B2-75 V1900/5 1872 C T /195/o0 04ib (1890) B2V6 1800/5 2575 C /195o 04 (1982) t/1400 B24~7 1800/5 2342 C T /1950 040 V (1805)15/1400 B2.-8 \j7 1800/5 1941 C T0P0} 040v (1800) 1i5/1400 WADc TR 54-206 92

TEST LOG (contw,) Specimetn Cross.uWber Type of Nflumber Section Cycle of Cycles Failure Remarks. (1)__ _(2 ) __ (3) (4 ) ( )) (6 ) M-252 Alloy (cont,) B2,9\ 2000/5 1229 C T/1950 ~~0415~ C- (1998)()5/i15/1400 ~7 /(1998).... B2-1l \77 2000/5 1)425 Tf 5/1400 o 045 v<'(1975)... i i. -' i i. l''. i...' _i _ _ i....i i _. i i.. i i i - B2-11 cli 2000/5 165o0 C T% o 90 040 V< (1892) atflJy -,;,-.'':'""..............,,,'..... _ "' _'".B-l. N./' ~ 2000/5 35552 C T10/500 ( 03 (2032) ^~~7~~7 /~[~24 2C/2200' 21900/5 274.5 C T 10/1500. 03 (1920) Di3 \7 2000/5 4079 C Tf 00 03V - (1980)0/1500j 02/22oo D-4 1900/5 4956 C T /1 03 (1920) D-5 7 1800/5 7839 C T ~,1000 WADC TR 54-206 95

TEST LOG (cont.) Specimei Cross Number Type of Number Seition- Cycle of Cycles Failure Reiarks (1) (2) (3) (4) (5) (6) HastelIy C (Cat) C-l 160o/5 l618 c Tj Sj 7045 r (1607) C-2 1600/5 224o C T,,00 056' (1595) 6/6 C.-5 \/1600/5 7546 C T 1/i0 047 v^- (t585) o'~~~~~~~- ~7~~ ~~(/22ool 7-4 717 1700/5 2737 C T O47 V (1683) 66 J 042 V<- (~702(1719) 6/ x8ao~ ag-'.~ r/.2o0 c>6 17cc/s 0)o8 c C- 7 1800/5 2138 C Tfl/22o00 0l42v<6 (1798) (16/6.ooj WADC TR 54-206 94

TEST LOG (cont,) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2)- (3) (4) (5) (6) Hastelloy C (Cast) (cont). 042 V<(1810) 16/1600 C-10 V 1900/5 4525 C /2"00 042 Vf- (1860) 2l6/l600j 0-11 1900/5 50C200 o^11 3020 1 1600 o43 (1s8o) C-12 2000/5 364 C T [1/2200 2 000/5 291 c T. /oo 059 (1990) 0-14 Not Used C-15 2000/5 624 C T l 6/2200i o0)4 (1988) He WADC TR 54-206 95

TEST LOG (cont.) Specimen Cross Number Type of Number SectLion Cycle of Cycles Failure Remarks (1.) ______ (2) (3) (4) (5) (6) 1amTZetal. K-lalK A 1 2000/5 3500 C Fractured 04 (1975).2 2000/5 269 C 040 ~(2000) 3 1700/5 2626 C Fractured 042 (1686) 4 1700/5 2525 C Fractured 04. v\s? (1719) V5 \/1600/5 18020+ 0 Stopped 040 -, (1592) 6 1800/5 6553 C Fractured o0 V; (18oo00) Keannametal K.152 —B 1 2000/5 L54 C Fraetured 2 \7iJ 2OO/5 545 C Fractured WADC TR 54-206 96

TEST LOG (cont.) Specimen Cross Number Type of Number Section Cycle of Cycles Failure Remarks (1) (2) (() (4) (5) (6) Kenn'aetal K-iL52-B (pont). 5 7 1800/5 591 C Fractured 05 4 1600/5 8511 0 Fractured 058 57 1800/5 251 C Fractured 04 6 77 1700/5 555 C Fractured 042 V Nimonic 8Q —A B4-1 40 1700/5 5574 C T8/1965) 040 v^- (1728) 16/1500 B4-2 771800/5 2919 C TF/1965 045 /1 (1775) B4-3 2000/5 789 C T/9 040 (2020) 16/1300 B4-4. 2000/5 849 C T 696 o 048 V^ (199o) 16/150(9 WADC TR 54-206 97

TEST LOG (cont*) SpeclMe~Epi Cnr~ ~NuMber Ty'p of Number Section Cycle of Cycles Failure Reemarks (z____) (2) _ (3) (4) (.(6) Ni:m inc 80-A (contot ) B4-5 2000/5 1078 C T8/1 0.7 \2(1982) /16/15300 B4-6 1900/5 1755 C T 1965 04o:' (1972) 16/1500) 777 1 1770 Tr8/1965 B4-7 1900/5 1910 C T 1965 057t (1895) 16/15oo B4,-8 \1700/5 17750 C T8/1965 05 (1720) 16/10ooJ P - - 4 - - w 1- -. — - -. I I I B4-9 1800/5. 298 C T{ (8/i965 o40 (1817) B14-10 7 1700/5 2560 C T8/965 058 ^(1710) 16/1500j B4-11 \ 1800/5 3029 C T 965o 1600/5 6510 C (8/196 5) 04. (oJ82) - BWPJDC^~ 04 1\(1600) 16/150 WADC TB 54-20698 ~ -z