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NASA NTRS2008

Processing and Structural Advantages of the Sylramic-iBN SiC Fiber for SiC/SiC Components

The successful high-temperature application of complex-shaped SiC/SiC components will depend on achieving as high a fraction of the as-produced fiber strength as possible during component fabrication and service. Key issues center on a variety of component architecture, processing, and service-related factors that can reduce fiber strength, such as fiber-fiber abrasion during architecture shaping, surface chemical attack during interphase deposition and service, and intrinsic flaw growth during high-temperature matrix formation and composite creep. The objective of this paper is to show that the NASA-developed Sylramic-iBN SiC fiber minimizes many of these issues for state-of-the-art melt-infiltrated (MI) SiC/BN/SiC composites. To accomplish this, data from various mechanical tests are presented that compare how different high performance SiC fiber types retain strength during formation of complex architectures, during processing of BN interphases and MI matrices, and during simulated composite service at high temperatures.

Yun, H. M.↗

NASA NTRS2002

Tensile Behavior of As-Fabricated and Burner-Rig Exposed SiC/SiC Composites with Hi-Nicalon Type-S Fibers

Tensile stress-strain curves were measured at room temperature and 1315 C for 2D-woven SiC/BN/SiC ceramic matrix composites (CMC) reinforced by two variations of Hi-Nicalon Type-S SiC fibers. These fibers, which contained a thin continuous carbon-rich layer on their as-produced surface, provided the as-fabricated CMC with good composite behavior and an ultimate strength and strain of -350 MPa and -0.5%, respectively. However, after un-stressed burner-rig exposure at 815 C for -100 hrs, CMC tensile specimens with cut edges and exposed interphases showed a significant decrease in ultimate properties with effectively no composite behavior. Microstructural observations show that the degradation was caused by internal fiber-fiber oxide bonding after removal of the carbon-rich fiber surface layer by the high-velocity combustion gases. On the other hand, SiC/BN/SiC CMC with Sylramic-iBN fibers without carbon-rich surfaces showed higher as-fabricated strength and no loss in strength after the same burner rig exposure. Based on the strong role of the carbon layer in these observations, a process method was developed and demonstrated for achieving better strength retention of Hi-Nicalon Type-S CMC during burner rig exposure. Other general approaches for minimizing this current deficiency with as-produced Type-S fibers are discussed.

Yun, H. M.↗

NASA NTRS1995

Effects of Thermal Treatment on Tensile Creep and Stress-Rupture Behavior of Hi-Nicalon SiC Fibers

Tensile creep and stress-rupture studies were conducted on Hi-Nicalon SiC fibers at 1200 and 1400 C in argon and air. Examined were as-received fibers as well as fibers annealed from 1400 to 1800 C for 1 hour in argon before testing. The creep and rupture results for these annealed fibers were compared to those of the as-received fibers to determine the effects of annealing temperature, test temperature, and test environment. Argon anneals up to 1500 C degrade room temperature strength of Hi-Nicalon fibers, but improve fiber creep resistance in argon or air by as much as 100% with no significant degradation in rupture strength. Argon anneals above 1500 C continue to improve fiber creep resistance when tested in argon, but significantly degrade creep resistance and rupture strength when tested in air. Decrease in creep resistance in air is greater at 1200 C than at 1400 C. Mechanisms are suggested for the observed behavior.

Yun, H. M.↗

NASA NTRS1994

Tensile Creep and Stress-rupture Behavior of Polymer Derived Sic Fibers

Tensile creep and stress-rupture studies were conducted on polymer derived Nicalon, Hi-Nicalon, and SiC/BN-coated Nicalon SiC fibers. Test conditions were temperatures from 1200 to 1400 C, stresses from 100 to 1600 MPa, stress application times up to 200 hours, and air, argon, and vacuum test environments. For all fibers, creep occurred predominantly in the primary stage. Hi-Nicalon had much higher 0.2 and 1 percent creep strengths than as-produced as well as-coated Nicalon fibers. The stress-rupture strength of Hi-Nicalon up to 100 hours was also higher than that of the coated and as-produced Nicalon fibers. SiC/BN coating on Nicalon increased only the short-term low-temperature rupture strength. Limited testing in argon and vacuum suggests that for all fiber types, creep and rupture resistances are reduced in comparison to the results in air. Possible mechanisms for the observed behavior are discussed.

Yun, H. M.↗

NASA NTRS1986

Polymer, metal, and ceramic matrix composites for advanced aircraft engine applications

Advanced aircraft engine research within NASA Lewis is being focused on propulsion systems for subsonic, supersonic, and hypersonic aircraft. Each of these flight regimes requires different types of engines, but all require advanced materials to meet their goals of performance, thrust-to-weight ratio, and fuel efficiency. The high strength/weight and stiffness/weight properties of resin, metal, and ceramic matrix composites will play an increasingly key role in meeting these performance requirements. At NASA Lewis, research is ongoing to apply graphite/polyimide composites to engine components and to develop polymer matrices with higher operating temperature capabilities. Metal matrix composites, using magnesium, aluminum, titanium, and superalloy matrices, are being developed for application to static and rotating engine components, as well as for space applications, over a broad temperature range. Ceramic matrix composites are also being examined to increase the toughness and reliability of ceramics for application to high-temperature engine structures and components.

Mcdanels, D. L.↗

NASA NTRS1986

Creep of chemically vapour deposited SiC fibres

The creep, thermal expansion, and elastic modulus properties for chemically vapor deposited SiC fibers were measured between 1000 and 1500 C. Creep strain was observed to increase logarithmically with time, monotonically with temperature, and linearly with tensile stress up to 600 MPa. The controlling activation energy was 480 + or - 20 kJ/mole. Thermal pretreatments near 1200 and 1450 C were found to significantly reduce fiber creep. These results coupled with creep recovery observations indicate that below 1400 C fiber creep is anelastic with negligible plastic component. This allowed a simple predictive method to be developed for describing fiber total deformation as a function of time, temperature, and stress. Mechanistic analysis of the property data suggests that fiber creep is the result of beta-SiC grain boundary sliding controlled by a small percent of free silicon in the grain boundaries.

Dicarlo, J. A.↗

NASA NTRS1985

High temperature metal and ceramic composites

The Materials Division at NASA Lewis is engaged in research and development efforts on behalf of fiber-reinforced composite materials that are lighter, stiffer, and more structurally reliable than conventional monolithic alloys and ceramics in applications that range from the cryogenic to the refractory. Attention is presently given to metal matrix composites, in which high performance depends on stiff, strong and thermally stable large diameter fibers, with chemically stable interfacial bonding and good coefficient of thermal expansion matching between fibers and matrices, and to ceramic matrix composites, in which intermediate strength interfacial bonds must allow cracks to propagate through the matrix only, while retaining good load transfer characteristics between fiber and matrix.

Signorelli, R. A.↗

NASA NTRS1985

Fibers for structurally reliable metal and ceramic composites

In their current state of development, commercially available reinforcing fibers fail to meet the requirements formulated for metal or ceramic matrix composites of sufficient strength and toughness. Attention is presently given to criteria for high strength and toughness in metal and ceramic matrix composites, as well as the approach adopted in fiber evaluation as a result of studies at the NASA Lewis Research Center. Two areas of special interest have been strength improvement in large diameter boron fibers for tough, impact-resistant boron/aluminum composites, and the evaluation of SiC fibers as reinforcement in tough ceramic-matrix composites with service temperatures of the order of 1400 C.

Dicarlo, J. A.↗

NASA NTRS1985

Polymer, metal and ceramic matrix composites for advanced aircraft engine applications

Advanced aircraft engine research within NASA Lewis is being focused on propulsion systems for subsonic, supersonic, and hypersonic aircraft. Each of these flight regimes requires different types of engines, but all require advanced materials to meet their goals of performance, thrust-to-weight ratio, and fuel efficiency. The high strength/weight and stiffness/weight properties of resin, metal, and ceramic matrix composites will play an increasingly key role in meeting these performance requirements. At NASA Lewis, research is ongoing to apply graphite/polyimide composites to engine components and to develop polymer matrices with higher operating temperature capabilities. Metal matrix composites, using magnesium, aluminum, titanium, and superalloy matrices, are being developed for application to static and rotating engine components, as well as for space applications, over a broad temperature range. Ceramic matrix composites are also being examined to increase the toughness and reliability of ceramics for application to high-temperature engine structures and components.

Mcdanels, D. L.↗

NASA NTRS1984

High performance fibers for structurally reliable metal and ceramic composites

Very few of the commercially available high performance fibers with low densities, high Young's moduli, and high tensile strengths possess all the necessary property requirements for providing either metal matrix composites (MMC) or ceramic matrix composites (CMC) with high structural reliability. These requirements are discussed in general and examples are presented of how these property guidelines are influencing fiber evaluation and improvement studies at NASA aimed at developing structurally reliable MMC and CMC for advanced gas turbine engines.

Dicarlo, J. A.↗

NASA NTRS1984

Creep of chemically vapor deposited SiC fibers

The creep, thermal expansion, and elastic modulus properties for chemically vapor deposited SiC fibers were measured between 1000 and 1500 C. Creep strain was observed to increase logarithmically with time, monotonically with temperature, and linearly with tensile stress up to 600 MPa. The controlling activation energy was 480 + or - 20 kJ/mole. Thermal pretreatments near 1200 and 1450 C were found to significantly reduce fiber creep. These results coupled with creep recovery observations indicate that below 1400 C fiber creep is anelastic with neglible plastic component. This allowed a simple predictive method to be developed for describing fiber total deformation as a function of time, temperature, and stress. Mechanistic analysis of the property data suggests that fiber creep is the result of beta-SiC grain boundary sliding controlled by a small percent of free silicon in the grain boundaries.

Dicarlo, J. A.↗

NASA NTRS1983

Measuring the Tensile Strength of B/AL Composites

Proposed nondestructive technique correlates damping measurements with material strength. Increasing axial damping and decreasing axial tensile strength are observed after 1-hour treatment of B/AL composites containing about 50 percent fiber. Damping was measured in vacuum at frequencies near 2,000 Hz, and tensile strength was normalized by maximum strength observed before thermally induced degradation.

Dicarlo, J. A.↗

NASA NTRS1983

Factors influencing the thermally-induced strength degradation of B/Al composites

Literature data related to the thermally-induced strength degradation of B/Al composites were examined in the light of fracture theories based on reaction-controlled fiber weakening. Under the assumption of a parabolic time-dependent growth for the interfacial reaction product, a Griffith-type fracture model was found to yield simple equations whose predictions were in good agreement with data for boron fiber average strength and for B/Al axial fracture strain. The only variables in these equations were the time and temperature of the thermal exposure and an empirical factor related to fiber surface smoothness prior to composite consolidation. Such variables as fiber diameter and aluminum alloy composition were found to have little influence. The basic and practical implications of the fracture model equations are discussed. Previously announced in STAR as N82-24297

Dicarlo, J. A.↗

NASA NTRS1982

Strength advantages of chemically polished boron fibers before and after reaction with aluminum

In order to determine their strength potential, the fracture properties of different types of commercial boron fibers were measured before and after application of secondary strengthening treatments. The principal treatments employed were a slight chemical polish, which removed low strength surface flaws, and a heat treatment in oxygen, which contracted the fibers and thereby compressed intrinsic bulk flaws. Those fiber types most significantly strengthened were 200 to 400 micrometers (8 to 16 mil) diameter boron on tungsten fibers produced in a single chemical vapor deposition reactor. The slight polish increased average tensile strenghts from 3.4 to 4.4 CN/m2 (500 to 640 ksi) and reduced coefficients of variation from about 15 to 3 percent. The oxygen heat treatment plus slight polish further improved average strengths to 5.5 GN/m2 (800 ksi) with coefficients near 3 percent. To ascertain whether these excellent properties could be retained after fabrication of B/Al composites, as produced and polished 203 micrometers (8 mil) fibers were thinly coated with aluminum, heat treated at B/Al fabrication temperatures, and then tested in tension and flexure at room temperature. The pre-polished fibers were observed to retain their superior strengths to higher temperatures than the as-produced fibers even though both were subjected to the same detrimental reaction with aluminum.

Dicarlo, J. A.↗

NASA NTRS1982

Factors influencing the thermally-induced strength degradation of B/Al composites

Literature data related to the thermally-induced strength degradation of B/Al composites were examined in the light of fracture theories based on reaction-controlled fiber weakening. Under the assumption of a parabolic time-dependent growth for the interfacial reaction product, a Griffith-type fracture model was found to yield simple equations whose predictions were in good agreement with data for boron fiber average strength and for B/Al axial fracture strain. The only variables in these equations were the time and temperature of the thermal exposure and an empirical factor related to fiber surface smoothness prior to composite consolidation. Such variables as fiber diameter and aluminum alloy composition were found to have little influence. The basic and practical implications of the fracture model equations are discussed.

Dicarlo, J. A.↗

NASA NTRS1981

Oxidation-induced contraction and strengthening of boron fibers

An investigation was conducted to measure and understand the physical and mechanical effects that occur in boron fibers during and after thermal treatment in a controlled oxygen argon gaseous mixture. Of principal concern was the optimization of this treatment as a secondary processing method for significantly improving fiber tensile strength. Strengthening was accomplished by an oxidation induced axial contraction of the fiber and a resulting axial compression of strength limiting flaws within the fiber's tungsten boride core. Various physical observations were used to develop mechanistic models for oxidation, contraction, and flow formation. Processing guidelines are discussed for possibly exceeding the 5.5 GN/sq m strength limit and also for achieving fiber strengthening during application of boron containing diffusion barrier coatings.

Dicarlo, J. A.↗

NASA NTRS1981

Oxidation-induced contraction and strengthening of boron fibers

An investigation of the physical and mechanical effects of thermal treatment in a controlled oxygen-argon atmosphere on boron fibers is reported, with attention to the optimization of such treatment as a secondary processing method for improvement of fiber strength. The strengthening mechanism is comprised of an oxidation-induced axial contraction of the fiber, accompanied by axial compression of strength-limiting flaws within the fiber's tungsten boride core. It was found that after an oxidation contraction of 0.3% near 900 C, and a slight surface etch near 100 C, the average tensile strength of 203-micron fibers increased from 500 to 800 ksi. Various physical observations are used to develop mechanistic models of oxidation, contraction, and the formation of new flaws in the boron sheath at contractions greater than 0.3%.

Dicarlo, J. A.↗

NASA NTRS1980

Predicting the time-temperature dependent axial failure of B/Al composites

Theoretical and experimental studies are reviewed whose objective was to gain insight into and predict the effects of time, temperature, and stress on the axial failure modes of boron fibers and B/Al composites. Owing to the inelastic nature of boron fiber deformation, it proved possible to develop simple creep functions which can be used to describe accurately the creep and fracture stress of as-produced fibers. Analysis of damping and stress data for B/6061 Al composites indicates that fiber creep and the effects of creep of fiber fracture are measurably reduced by the composite fabrication process.

Dicarlo, J. A.↗