Nickel aluminum bronze (NAB) alloys are used in naval and maritime applications for their excellent corrosion resistance under the influence of seawater. One application involves the use of a NAB butterfly valve within a NAB fluid line to control fluid flow of seawater. Due to the chaotic environment, the corrosion rate of the NAB tubing downstream from the valve increases significantly. The disc angle at which the valve alters fluid flow causes an increase in the fluid velocity and an increase in the turbulence produced on the downstream side of the valve. These fluid conditions contribute to the increase in the corrosion rate of the NAB piping downstream from the valve. This thesis aims to characterize how the change in the disc angle of the butterfly valve causes a change in the erosion-corrosion rate of NAB downstream from the valve. A butterfly valve is simulated using orifice plates of varying diameters to mimic flow conditions at different disc angles. An orifice plate is a simple device with a hole in its center that is designed to restrict fluid flow across a fluid line. Under the same hydrodynamic conditions, the orifice produces nearly the exact same flow coefficients as the valve. At a volumetric flowrate of 0.00757 m^3/s a total of eight locations found along the liquid/metal interface produced pitting sites. The average passivation layer thickness is also measured. / Master of Science

Approved for public release, distribution is unlimited / The effect of friction-stir processing (FSP) on the microstructure of a cast nickel-aluminum bronze (NAB) material has been characterized by various micro-analytical methods including orientation imaging microscopy (OIM). Cast NAB is widely utilized in the production of propellers for the surface ships and submarines of the U.S. Navy due to excellent corrosion-resistance. New applications require improved mechanical properties that may be attainable using FSP to achieve localized microstructure modification. Friction between a rotating tool and the surface of the material results in a *stirring* action that, in turn, produces adiabatic heating and local softening of the material. The tool rotation results in very large shear deformations in the softened regions and thus microstructure refinement and homogenization; in effect FSP may convert an as-cast microstructure to a wrought condition in the absence of macroscopic shape change. In as-cast material, results of optical and scanning electron microscopy (using energy dispersive analysis) show an ` (FCC) matrix containing globular and particulate dispersions that correspond to the *I, *II and *IV second phases; these represent various morphologies of the Fe3Al intermetallic compound, which has a D03 structure. Also present are lamellar particles of *III, which is NiAl and has a B2 structure. The grain size in the ` matrix is ~ 1 mm. In OIM, the microtexture and microstructure in the ` (FCC) matrix may be readily obtained and analyzed. However, interatom distances in the Fe3Al and NiAl phases differ by only about one percent and so these phases are not distinguishable from one another during OIM. Altogether, microstructure and microtexture analysis showed that there are several regions in the thermomechanically affected zone (TMAZ) of a material subjected to FSP. From base material inward toward the TMAZ, these include: annealing effects in undeformed base material; a region just inside the TMAZ in which grain deformation and C-type shear deformation textures are observed; regions of highly refined and recrystallized grains further inside the TMAZ, wherein the grain size is < 5æm; and, finally, regions of elongated, banded and twinned grain structures that suggest grain growth following recrystalliztion. / Lieutenant, United States Navy

Approved for public release, distribution is unlimited / The extreme strain, strain rate and temperature gradients during Friction Stir Processing (FSP) render measurement of key parameters in the stir zone infeasible with common methods. The objective of this research was to separate the effects that temperature and deformation in an experimental study of the microstructure and mechanical properties of Ni-AL bronze (NAB). This was accomplished by subjecting as-cast NAB material to several isothermal annealing and quenching treatments as well as isothermal hot rolling processes. Sufficient material was generated to provide results and data for subsequent optical microscopy, tensile, & hardness tests. All results were then compared to similar data collected from previous works completed here at Naval Postgraduate School and with other DARPA FSP program participants. During the course of this work correlations were drawn between FSP material and the material subjected to isothermal hotworking, which may enhance our understanding of the roles that various FSP process parameters have on the microstructural transformation sequence within this material. The hot-rolling study conducted here suggests that FSP process parameters leading to severe deformation at temperatures between 950-1000 C in the NAB material provides high ductility (elongation approximately 28%) with moderate strengths. / Lieutenant, United States Coast Guard