Engineering topics

Brewer, David N.

Publications and source records attributed to Brewer, David N..

17 records

NASA NTRS2013

Wear and Reactivity Studies of Melt infiltrated Ceramic Matrix Composite

As interest grows in the use of ceramic matrix composites (CMCs) for critical gas turbine engine components, the effects of the CMCs interaction with the adjoining structure needs to be understood. A series of CMC/material couples were wear tested in a custom elevated temperature test rig and tested as diffusion couples, to identify interactions. Specifically, melt infiltrated silicon carbide/silicon carbide (MI SiC/SiC) CMC was tested in combination with a nickel-based super alloy, Waspaloy, a thermal barrier coating, Yttria Stabilized Zirconia (YSZ), and a monolithic ceramic, silicon nitride (Si3N4). To make the tests more representative of actual hardware, the surface of the CMC was kept in the as-received state (not machined) with the full surface features/roughness present. Test results include: scanning electron microscope characterization of the surfaces, micro-structural characterization, and microprobe analysis.

Jarmon, David C.↗

NASA NTRS2006

Predicting Lifetime of a Thermomechanically Loaded Component

NASALIFE is a computer program for predicting the lifetime, as affected by low cycle fatigue (LCF) and creep rupture, of a structural component subject to temporally varying, multiaxial thermomechanical loads. The component could be, for example, part of an aircraft turbine engine. Empirical data from LCF tests, creep rupture tests, and static tensile tests are used as references for predicting the number of missions the component can withstand under a given thermomechanical loading condition. The user prepares an input file containing the creep-rupture and cyclic-fatigue information, temperature-dependent material properties, and mission loading and control flags. The creep rupture information can be entered in tabular form as stress versus life or by means of parameters of the Larson-Miller equation. The program uses the Walker mean-stress model to adjust predicted life for ranges of the ratio between the maximum and minimum stresses. Data representing complex load cycles are reduced by the rainflow counting method. Miner's rule is utilized to combine the damage at different load levels. Finally, the program determines the total damage due to creep and combines it with the fatigue damage due to the cyclic loading and predicts the approximate number of missions a component can endure before failing.

Murthy, Pappu L. N.↗

NASA NTRS2006

Foreign Object Damage in a Gas-Turbine Grade Silicon Nitride by Spherical Projectiles of Various Materials

Assessments of foreign object damage (FOD) of a commercial, gas-turbine grade, in situ toughened silicon nitride ceramic (AS800, Honeywell Ceramics Components) were made using four different projectile materials at ambient temperature. AS800 flexure target specimens rigidly supported were impacted at their centers in a velocity range from 50 to 450 m/s by spherical projectiles with a diameter of 1.59 mm. Four different projectile materials were used including hardened steel, annealed steel, silicon nitride ceramic, and brass. Post-impact strength of each target specimen impacted was determined as a function of impact velocity to appraise the severity of local impact damage. For a given impact velocity, the degree of strength degradation was greatest for ceramic balls, least for brass balls, and intermediate for annealed and hardened steel balls. For steel balls, hardened projectiles yielded more significant impact damage than annealed counterparts. The most important material parameter affecting FOD was identified as hardness of projectiles. Impact load as a function of impact velocity was quasi-statically estimated based on both impact and static indentation associated data.

Choi, Sung R.↗

NASA NTRS2006

Ceramic Matrix Composite Vane Subelement Burst Testing

Burst tests were performed on Ceramic Matrix Composite (CMC) vane specimens, manufactured by two vendors, under the Ultra Efficient Engine Technology (UEET) project. Burst specimens were machined from the ends of 76mm long vane sub-elements blanks and from High Pressure Burner Rig (HPBR) tested specimens. The results of burst tests will be used to compare virgin specimens with specimens that have had an Environmental Barrier Coating (EBC) applied, both HPBR tested and untested, as well as a comparison between vendors.

Brewer, David N.↗

NASA NTRS2005

Role of Probabilistic Micromechanics Modeling in Establishing Design Allowables in Composites

One of the major challenges in designing with any new material, and particularly with advanced composite materials, is the fidelity of material design allowables. In the case of composite materials, the concern arises from the inherent nature of these materials, i.e., their heterogeneous make-up and the various factors that affect their properties in a specific design environment. Composites have various scales - micro, macro, laminate and structural, as well as numerous other fabrication related parameters. Many advanced composites in aerospace applications involve complex two- and three-dimensional fiber architectures and requires high-temperature processing. Since there are uncertainties associated with each of these, the observed behavior of composite materials shows scatter. Evaluating the effect of each of these variables on the observed scatter in composite properties solely by teSting is cost and time prohibitive. One alternative is to evaluate these effects by computational simulation. The authors have developed probabilistic composite micromechanics techniques by combining woven composite micromechanics and Fast Probability Integration (FPI) techniques to address these issues. In this paper these techniques will be described and demonstrated through selected examples. Results in the form of cumulative distribution functions (CDF) of the composite properties of a MI (melt-infiltrated) SiC/SiC (silicon carbide fiber in a silicon carbide matrix) Composite will be presented. A CDF is a relationship defined by the value of the property (the response variable) with respect to the cumulative probability of occurrence. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Sensitivity information is very valuable in quality control. How these results can be utilized to develop design allowables so that these materials may be used by structural analysts/designers will also be discussed.

Mital, Subodh K.↗

NASA NTRS2005

Comparison of Elevated Temperature Tensile Properties and Fatigue Behavior of Two Variants of a Woven SiC/SiC Composite

Tensile properties (elastic modulus, proportional limit strength, in-plane tensile strength, and strain at failure) of two variants of a woven SiC/SiC composite, manufactured during two separate time periods (9/99 and 1/01), were determined at 1038 and 1204 C by conducting tensile tests on specimens machined from plates. Continuous cycling fatigue tests (R = 0.05) and 20 cpm) were also conducted at the same two temperatures on specimens from both composites. In this study, average tensile properties, 95% confidence intervals associated with the tensile properties, and geometric mean fatigue lives of both composite materials are compared. The observed similarities and differences in the tensile properties are highlighted and an attempt is made to understand the relationship, if any, between the tensile properties and the fatigue behaviors of the two woven composites.

Kalluri, Sreeramesh↗

NASA NTRS2005

Effect of Projectile Materials on Foreign Object Damage of a Gas-Turbine Grade Silicon Nitride

Foreign object damage (FOD) behavior of AS800 silicon nitride was determined using four different projectile materials at ambient temperature. The target test specimens rigidly supported were impacted at their centers by spherical projectiles with a diameter of 1.59 mm. Four different types of projectiles were used including hardened steel balls, annealed steel balls, silicon nitride balls, and brass balls. Post-impact strength of each target specimen impacted was determined as a function of impact velocity to better understand the severity of local impact damage. The critical impact velocity where target specimens fail upon impact was highest with brass balls, lowest with ceramic ball, and intermediate with annealed and hardened steel balls. Degree of strength degradation upon impact followed the same order as in the critical impact velocity with respect to projectile materials. For steel balls, hardened projectiles yielded more significant impact damage than annealed counterparts. The most important material parameter affecting FOD was identified as hardness of projectiles and was correlated in terms of critical impact velocity, impact deformation, and impact load.

Choi, Sung R.↗

NASA NTRS2004

Probabilistic Analysis of a SiC/SiC Ceramic Matrix Composite Turbine Vane

To demonstrate the advanced composite materials technology under development within the Ultra-Efficient Engine Technology (UEET) Program, it was planned to fabricate, test, and analyze a turbine vane made entirely of silicon carbide-fiber-reinforced silicon carbide matrix composite (SiC/SiC CMC) material. The objective was to utilize a five-harness satin weave melt-infiltrated (MI) SiC/SiC composite material developed under this program to design and fabricate a stator vane that can endure 1000 hours of engine service conditions. The vane was designed such that the expected maximum stresses were kept within the proportional limit strength of the material. Any violation of this design requirement was considered as the failure. This report presents results of a probabilistic analysis and reliability assessment of the vane. Probability of failure to meet the design requirements was computed. In the analysis, material properties, strength, and pressure loading were considered as random variables. The pressure loads were considered normally distributed with a nominal variation. A temperature profile on the vane was obtained by performing a computational fluid dynamics (CFD) analysis and was assumed to be deterministic. The results suggest that for the current vane design, the chance of not meeting design requirements is about 1.6 percent.

Murthy, Pappu L. N.↗

NASA NTRS2004

An Assessment of Variability in the Average Tensile Properties of a Melt-Infiltrated SiC/SiC Composite

Woven SiC/SiC Ceramic Matrix Composites (CMCs), manufactured by the slurry-cast, melt-infiltration process are under consideration as combustor liner materials in aircraft gas turbine engines. Tensile properties (elastic modulus, proportional limit strength, in-plane tensile strength and strain to failure) of the CMC, manufactured during two separate time periods (9/99 and 1/01) were determined at 816 and 1024 C by conducting tensile tests on specimens machined from the CMC plates. A total of 24 tensile tests were conducted for each temperature and CMC variant combination. In this study average tensile properties of the two cMC variants were statistically compared to evaluate significant differences, if any, within the CMC's properties.

Kalluri, Sreeramesh↗

NASA NTRS2004

Computation of Variability in the Average Thermal and Mechanical Properties of a Melt-infiltrated Sic/sic Composite

Thermal conductivity and tensile properties (elastic modulus, proportional limit strength, inplane tensile strength, and strain to failure) of a SiC/SiC composite were experimentally determined at 816 and 1204 C. Tests were performed at room temperature on the same material to obtain interlaminar shear and tensile strength. For each thermal and mechanical property 24 tests were conducted to capture the variation. A random sampling method was used to quantify the variability exhibited by the mean values of the thermal and mechanical properties. The minimum number of tests required to characterize the mean value of each thermal or mechanical property for the composite was determined by varying the group size of the random sample.

Kalluri, Sreeramesh↗

NASA NTRS2002

RQL Sector Rig Testing of SiC/SiC Combustor Liners

Combustor liners, manufactured from silicon carbide fiber-reinforced silicon carbide (SiC/SiC) were tested for 260 hr using a simulated gas turbine engine cycle. This report documents the results of the last 56 hr of testing. Damage occurred in one of the six different components that make up the combustor liner set, the rich zone liner. Cracks in the rich zone liner initiated at the leading edge due to stresses resulting from the component attachment configuration. Thin film thermocouples and fiber optic pyrometers were used to measure the rich zone liner's temperature and these results are reported.

Verrilli, Michael J.↗

NASA NTRS2002

High Temperature Tensile Properties and Fatigue Behavior of a Melt-Infiltrated SiC/SiC Composite

High temperature fatigue behavior of a woven, SiC/SiC ceramic matrix composite (CMC) was investigated in air at two temperatures. The reinforcement for the CMC consisted of 5HS Sylramic(Trademark) fabric with a [0deg/90deg]4s lay-up. The SiC matrix material was infiltrated into the fiber-preform with a slurry-cast, melt-infiltration process. Tensile and fatigue test specimens were machined from the CMC plates. Initially tensile tests were conducted to obtain the average values of tensile properties at 1038 and 1204 C. Subsequently, low-cycle fatigue (LCF) tests with zero and two-hour hold-times at the maximum stress were conducted at the same two temperatures. Fatigue life data generated in the LCF tests were used to determine the geometric mean fatigue lives. In this paper, the tensile behavior and the fatigue durability of the CMC determined under different loading conditions are documented. In addition, reductions observed in the cyclic lives of the composite due to the two hour hold-time at maximum tensile stress are discussed.

Kalluri, Sreeramesh↗

NASA NTRS2001

Life Prediction Issues in Thermal/Environmental Barrier Coatings in Ceramic Matrix Composites

Issues and design requirements for the environmental barrier coating (EBC)/thermal barrier coating (TBC) life that are general and those specific to the NASA Ultra-Efficient Engine Technology (UEET) development program have been described. The current state and trend of the research, methods in vogue related to the failure analysis, and long-term behavior and life prediction of EBCITBC systems are reported. Also, the perceived failure mechanisms, variables, and related uncertainties governing the EBCITBC system life are summarized. A combined heat transfer and structural analysis approach based on the oxidation kinetics using the Arrhenius theory is proposed to develop a life prediction model for the EBC/TBC systems. Stochastic process-based reliability approach that includes the physical variables such as gas pressure, temperature, velocity, moisture content, crack density, oxygen content, etc., is suggested. Benefits of the reliability-based approach are also discussed in the report.

Shah, Ashwin R.↗

NASA NTRS1997

Stressed Oxidation of C/SiC Composites

Constant load, stressed oxidation testing was performed on T-300 C/SiC composites with a SiC seal coat. Test conditions included temperatures ranging from 350 C to 1500 C at stresses of 69 MPa and 172 MPa (10 and 25 ksi). The coupon subjected to stressed oxidation at 550 C/69 MPa for 25 hours had a room temperature residual strength one-half that of the as-received coupons. The coupon tested at the higher stress and all coupons tested at higher temperatures failed in less than 25 hr. Microstructural analysis of the fracture surfaces, using SEM (scanning electron microscopy), revealed the formation of reduced cross-sectional fibers with pointed tips. Analysis of composite cross-sections show pathways for oxygen ingress. The discussion will focus on fiber/matrix interphase oxidation and debonding as well as the formation and implications of the fiber tip morphology.

Halbig, Michael C.↗

NASA NTRS1993

Analytical stress intensity solution for the Stable Poisson Loaded specimen

An analytical calibration of the Stable Poisson Loaded (SPL) specimen is presented. The specimen configuration is similar to the ASTM E-561 compact-tension specimen with displacement controlled wedge loading used for R-curve determination. The crack mouth opening displacements (CMODs) are produced by the diametral expansion of an axially compressed cylindrical pin located in the wake of a machined notch. Due to the unusual loading configuration, a three-dimensional finite element analysis was performed with gap elements simulating the contact between the pin and specimen. In this report, stress intensity factors, CMODs, and crack displacement profiles, are reported for different crack lengths and different contacting conditions. It was concluded that the computed stress intensity factor decreases sharply with increasing crack length thus making the SPL specimen configuration attractive for fracture testing of brittle, high modulus materials.

Ghosn, Louis J.↗

NASA NTRS1992

Controlled crack growth specimen for brittle systems

A pure Mode 1 fracture specimen and test procedure has been developed which provides extended, stable, through-thickness crack growth in ceramics and other brittle, nonmetallic materials. Fixed displacement loading, applied at the crack mouth, promotes stable crack extension by reducing the stored elastic strain energy. Extremely fine control of applied displacements is achieved by utilizing the Poisson's expansion of a compressively loaded cylindrical pin. Stable cracks were successfully grown in soda-lime glass and monolithic Al2O3 for lengths in excess of 2O mm without uncontrollable catastrophic failure.

Calomino, Anthony M.↗

NASA NTRS1990

Controlled crack growth specimen for brittle systems

Calomino, Anthony M.↗