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NASA NTRS1996

Hot Hydrogen Exposure Degradation of the Strength of Mullite

This study deals with the corrosion of near stoichiometric mullite (3Al2O3-2SiO2) by pure dry hydrogen gas. Exposure of the mullite samples was at temperatures of 1050 and 1250 C for times up to 500 hours. Preferential attack of the alumino-silicate glass present in the grain boundaries of the mullite occurred after 125 hours at 1250 C. Hydrogen scrubbing of the SiO2 from the glassy grain boundaries and the mullite grains yielded a porous alumina-rich surface. The room temperature strength increased after short exposure times at 1250 C (up to 125 hours), then decreased by 53 percent after exposure for 500 hours. At 1050 C, all exposure times (25 to 500 hours) decreased the strength. After 500 hours in hydrogen at 1050 C, the room temperature strength of mullite decreased 22 percent. We also observed a rapid 25 percent strength loss after short exposure times at 1050 C. This is attributed to the calcium/hydrogen assisted crystallization of the glassy, grain-boundary phase.

Herbell, Thomas P.↗

NASA NTRS1992

Ceramic matrix composites for rocket engine turbine applications

A program to establish the potential for introducing fiber reinforced ceramic matrix composites (FRCMC) in future rocket engine turbopumps was instituted in 1987. A brief summary of the overall program (both contract and in-house research) is presented. Tests at NASA Lewis include thermal upshocks in a hydrogen/oxygen test rig capable of generating heating rates up to 2500 C/sec. Post thermal upshock exposure evaluation includes the measurement of residual strength and failure analysis. Test results for monolithic ceramics and several FRCMC are presented. Hydrogen compatibility was assessed by isothermal exposure of monolithic ceramics in high temperature gaseous hydrogen plus water vapor.

Herbell, Thomas P.↗

NASA NTRS1992

Enabling propulsion materials for high-speed civil transport engines

NASA Headquarters and LeRC have advocated an Enabling Propulsion Materials Program (EPM) to begin in FY-92. The High Speed Research Phase 1 program which began in FY-90 has focused on the environmental acceptability of a High Speed Civil Transport (HSCT). Studies by industry, including Boeing, McDonnell Douglas, GE Aircraft Engines, and Pratt & Whitney Aircraft, and in-house studies by NASA concluded that NO(x) emissions and airport noise reduction can only be economically achieved by revolutionary advancements in materials technologies. This is especially true of materials for the propulsion system where the combustor is the key to maintaining low emissions, and the exhaust nozzle is the key to reducing airport noise to an acceptable level. Both of these components will rely on high temperature composite materials that can withstand the conditions imposed by commercial aircraft operations. The proposed EPM program will operate in conjunction with the HSR Phase 1 Program and the planned HSR Phase 2 program slated to start in FY-93. Components and subcomponents developed from advanced materials will be evaluated in the HSR Phase 2 Program.

Stephens, Joseph R.↗

NASA NTRS1992

Monolithic ceramics

A development history and current development status evaluation are presented for SiC and Si3N4 monolithic ceramics. In the absence of widely sought improvements in these materials' toughness, and associated reliability in structural applications, uses will remain restricted to components in noncritical, nonman-rated aerospace applications such as cruise missile and drone gas turbine engine components. In such high temperature engine-section components, projected costs lie below those associated with superalloy-based short-life/expendable engines. Advancements are required in processing technology for the sake of fewer and smaller microstructural flaws.

Herbell, Thomas P.↗

NASA NTRS1992

Aerospace applications

Aerospace applications of ceramics and ceramic composites are discussed. The use of these materials in space propulsion, space power, aerospace vehicles, and space structures is examined.

Levine, Stanley R.↗

NASA NTRS1991

Thermal shock fiber-reinforced ceramic matrix composites

Monolithic silicon carbide and silicon nitride and a Nicalon fiber reinforced silicon carbide composite were subjected to severe thermal shock conditions via impingement of a hydrogen-oxygen flame. Surface heating rates of 1000 C/sec to 2500 C/sec were generated. The performance of the monolithic reference materials are compared and contrasted to the significantly greater thermal shock resistance of the composite. Ultrasonic and radiographic NDE techniques were used to evaluate the integrity of the composite subsequent to thermal shock. Tensile tests were performed to determine the residual tensile strength and modulus. Physical property changes are discussed as a function of number and severity of thermal shock cycles.

Eckel, Andrew J.↗

NASA NTRS1991

Ceramic composites for rocket engine turbines

The use of ceramic materials in the hot section of the fuel turbopump of advanced reusable rocket engines promises increased performance and payload capability, improved component life and economics, and greater design flexibility. Severe thermal transients present during operation of the Space Shuttle Main Engine (SSME), push metallic components to the limit of their capabilities. Future engine requirements might be even more severe. In phase one of this two-phase program, performance benefits were quantified and continuous fiber reinforced ceramic matrix composite components demonstrated a potential to survive the hostile environment of an advaced rocket engine turbopump.

Herbell, Thomas P.↗

NASA NTRS1991

Ceramic composites for rocket engine turbines

The use of ceramic materials in the hot section of the fuel turbopump of advanced reusable rocket engines promises increased performance and payload capability, improved component life and economics, and greater design flexibility. Severe thermal transients present during operation of the Space Shuttle Main Engine (SSME), push metallic components to the limit of their capabilities. Future engine requirements might be even more severe. In phase one of this two-phase program, performance benefits were quantified and continuous fiber reinforced ceramic matrix composite components demonstrated a potential to survive the hostile environment of an advanced rocket engine turbopump.

Herbell, Thomas P.↗

NASA NTRS1991

Thermal shock of fiber reinforced ceramic matrix composites

Monolithic silicon carbide and silicon nitride and a Nicalon fiber reinforced silicon carbide composite were subjected to severe thermal shock conditions via impingement of a hydrogen-oxygen flame. Surface heating rates of 1000 C/sec to 2500 C/sec were generated. The performance of the monolithic reference materials are compared and contrasted to the significantly greater thermal shock resistance of the composite. Ultrasonic and radiographic NDE techniques were used to evaluate the integrity of the composite subsequent to thermal shock. Tensile tests were performed to determine the residual tensile strength and modulus. Physical property changes are discussed as a function of number and severity of thermal shock cycles.

Eckel, Andrew J.↗

NASA NTRS1991

Effect of hydrogen on the strength and microstructure of selected ceramics

Ceramics in monolithic form and as composite constituents in the form of fibers, matrices, and coatings are currently being considered for a variety of high-temperature applications in aeronautics and space. Many of these applications involve exposure to a hydrogen-containing environment. The compatibility of selected ceramics in gaseous high-temperature hydrogen is assessed. Environmental stability regimes for the long term use of ceramic materials are defined by the parameters of temperature, pressure, and moisture content. Thermodynamically predicted reactions between hydrogen and several monolithic ceramics are compared with actual performance in a controlled environment. Morphology of hydrogen attack and the corresponding strength degradation is reported for silicon carbide, silicon nitride, alumina, magnesia, and mullite.

Herbell, Thomas P.↗

NASA NTRS1990

Effect of hydrogen on the strength and microstructure of selected ceramics

Ceramics in monolithic form and as composite constituents in the form of fibers, matrices, and coatings are currently being considered for a variety of high-temperature applications in aeronautics and space. Many of these applications involve exposure to a hydrogen-containing environment. The compatibility of selected ceramics in gaseous high-temperature hydrogen is assessed. Environmental stability regimes for the long term use of ceramic materials are defined by the parameters of temperature, pressure, and moisture content. Thermodynamically predicted reactions between hydrogen and several monolithic ceramics are compared with actual performance in a controlled environment. Morphology of hydrogen attack and the corresponding strength degradation is reported for silicon carbide, silicon nitride, alumina, magnesia, and mullite.

Herbell, Thomas P.↗

NASA NTRS1990

Effect of high temperature hydrogen exposure on the strength and microstructure of mullite

The corrosion of near stoichiometric mullite (3Al2O3-2SiO2) by pure dry hydrogen gas was studied at 1050 and 1250 C for times up to 500 hr. The hydrogen preferentially attacked the grain boundaries of the mullite where an aluminosilicate glass was present. Corrosion of the mullite grains was observed after 125 hr at 1250 C. The hydrogen reaction removed SiO2 from the glassy grain boundaries and the mullite grains resulting in a porous alumina rich surface. At 1250 C the strength increased after short exposure times (at least up to 125 hr) and decreased by 53 percent after 500 hr. At 1050 C, all exposure times (25 to 500 hr) decreased the strength. At 500 hr room temperature strength of mullite exposed to 1050 C was reduced by 22 percent. The strength reduction after short exposure times at 1050 C is attributed to crystallization of the grain boundary glass phase.

Herbell, Thomas P.↗

NASA NTRS1989

Grinding Si3N4 Powder In Si3N4 Equipment

Three methods of grinding compared. Report based on study of grinding silicon nitride powder in preparation for sintering into solid ceramic material. Attrition, vibratory, and ball mills lined with reaction-bonded silicon nitride tested. Rates of reduction of particle sizes and changes in chemical compositions of powders measured so grinding efficiences and increases in impurity contents from wear of mills and media evaluated for each technique.

Herbell, Thomas P.↗

NASA NTRS1988

Ceramic matrix composites in simulated SSME environments

Future Space Shuttle Main Engine (SSME)-type rocket engines can benefit from the use of fiber-reinforced ceramix matrix composites (FRCMC). Ceramics reinforced with long continuous fibers exhibit improved tolerance to severe thermomechanical and environmental exposures. An in-house NASA-Lewis program to evaluate the durability of FRCMC in simulated SSME environments is described. Primary tests involve multiple (one second) exposures of FRCMC specimens in a hydrogen/oxygen rocket test rig. This rig generates surface heating rates of 1000 to 2500 C/second. The FRCMC durability evaluation involves measurement of retained strength as a function of thermal shock severity and number of upshock cycles. Preliminary test results for monolithic silicon nitride (Si3N4) and silicon carbide (SiC), and one type of silicon based FRCMC, are presented. The test data are examined in terms of simple thermal shock theory.

Herbell, Thomas P.↗

NASA NTRS1988

Effect of high-temperature hydrogen exposure on sintered alpha-SiC

Sintered alpha-silicon carbide was exposed to pure, dry hydrogen at high temperatures for times up to 500 hr. Weight loss and corrosion were seen after 50 hr at temperatures as low as 1000 C. Corrosion of SiC by hydrogen produced grain boundary deterioration at 1100 C and a mixture of grain and grain boundary deterioration at 1300 C. Statistically significant strength reductions were seen in samples exposed to hydrogen for times greater than 50 hr and temperatures above 1100 C. Critical fracture origins were identified by fractography as either general grain boundary corrosion at 1100 C or as corrosion pits at 1300 C. A maximum strength decrease of approximately 33 percent was seen at 1100 and 1300 C after 500 hr exposure to hydrogen. A computer assisted thermodynamic program was also used to predict possible reaction species of SiC and hydrogen.

Hallum, Gary W.↗