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NASA NTRS2009

Self-Assembling, Flexible, Pre-Ceramic Composite Preforms

In this innovation, light weight, high temperature, compact aerospace structures with increased design options are made possible by using self-assembling, flexible, pre-ceramic composite materials. These materials are comprised of either ceramic or carbon fiber performs, which are infiltrated with polymer precursors that convert to ceramics upon thermal exposure. The preform architecture can vary from chopped fibers formed into blankets or felt, to continuous fibers formed into a variety of 2D or 3D weaves or braids. The matrix material can also vary considerably. For demonstration purposes, a 2D carbon weave was infiltrated with a SiC polymer precursor. The green or unfired material is fabricated into its final shape while it is still pliable. It is then folded or rolled into a much more compact shape, which will occupy a smaller space. With this approach, the part remains as one continuous piece, rather than being fabricated as multiple sections, which would require numerous seals for eventual component use. The infiltrated preform can then be deployed in-situ. The component can be assembled into its final shape by taking advantage of the elasticity of the material, which permits the structure to unfold and spring into its final form under its own stored energy. The pre-ceramic composites are converted to ceramics and rigidized immediately after deployment. The final ceramic composite yields a high-temperature, high-strength material suitable for a variety of aerospace structures. The flexibility of the material, combined with its high-temperature structural capacity after rigidization, leads to a less complex component design with an increased temperature range. The collapsibility of these structures allows for larger components to be designed and used, and also offers the potential for increased vehicle performance. For the case of collapsible nozzle extensions, a larger nozzle, and thus a larger nozzle exit plane, is possible because interference with surrounding structures can be avoided in the collapsed state. The larger exit plane leads to an increase in expansion area ratio, which has the potential to increase thrust and overall rocket performance. In general, the use of advanced ceramic materials can lead to improved engine and vehicle performance. The ceramics can run hotter, so less cooling is required. Fuel to coolant ratios can be balanced more readily to reduce weight. Engine efficiency can also be increased with hotter combustion and exhaust temperatures. In addition, the ceramic composites themselves can reduce the component weight by as much as 50 percent, which can translate into greater payload for the vehicle

Jaskowiak, Martha H.↗

NASA NTRS2010

Ceramic Integration Technologies for Advanced Energy Systems: Critical Needs, Technical Challenges, and Opportunities

Advanced ceramic integration technologies dramatically impact the energy landscape due to wide scale application of ceramics in all aspects of alternative energy production, storage, distribution, conservation, and efficiency. Examples include fuel cells, thermoelectrics, photovoltaics, gas turbine propulsion systems, distribution and transmission systems based on superconductors, nuclear power generation and waste disposal. Ceramic integration technologies play a key role in fabrication and manufacturing of large and complex shaped parts with multifunctional properties. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various needs, challenges, and opportunities in design, fabrication, and testing of integrated similar (ceramic ceramic) and dissimilar (ceramic metal) material www.nasa.gov 45 ceramic-ceramic-systems have been discussed. Experimental results for bonding and integration of SiC based Micro-Electro-Mechanical-Systems (MEMS) LDI fuel injector and advanced ceramics and composites for gas turbine applications are presented.

Singh, Mrityunjay↗

NASA NTRS2013

Nano-Ceramic Coated Plastics

Plastic products, due to their durability, safety, and low manufacturing cost, are now rapidly replacing cookware items traditionally made of glass and ceramics. Despite this trend, some still prefer relatively expensive and more fragile ceramic/glassware because plastics can deteriorate over time after exposure to foods, which can generate odors, bad appearance, and/or color change. Nano-ceramic coatings can eliminate these drawbacks while still retaining the advantages of the plastic, since the coating only alters the surface of the plastic. The surface coating adds functionality to the plastics such as self-cleaning and disinfectant capabilities that result from a photocatalytic effect of certain ceramic systems. These ceramic coatings can also provide non-stick surfaces and higher temperature capabilities for the base plastics without resorting to ceramic or glass materials. Titanium dioxide (TiO2) and zinc oxide (ZnO) are the candidates for a nano-ceramic coating to deposit on the plastics or plastic films used in cookware and kitchenware. Both are wide-bandgap semiconductors (3.0 to 3.2 eV for TiO2 and 3.2 to 3.3 eV for ZnO), so they exhibit a photocatalytic property under ultraviolet (UV) light. This will lead to decomposition of organic compounds. Decomposed products can be easily washed off by water, so the use of detergents will be minimal. High-crystalline film with large surface area for the reaction is essential to guarantee good photocatalytic performance of these oxides. Low-temperature processing (<100 C) is also a key to generating these ceramic coatings on the plastics. One possible way of processing nanoceramic coatings at low temperatures (< 90 C) is to take advantage of in-situ precipitated nanoparticles and nanostructures grown from aqueous solution. These nanostructures can be tailored to ceramic film formation and the subsequent microstructure development. In addition, the process provides environment- friendly processing because of the aqueous solution. Low-temperature processing has also shown versatility to generate various nanostructures. The growth of low-dimensional nanostructures (0-D, 1-D) provides a means of enhancing the crystallinity of the solution-prepared films that is of importance for photocatalytic performance. This technology can generate durable, fully functional nano-ceramic coatings (TiO2, ZnO) on plastic materials (silicone, Teflon, PET, etc.) that can possess both photocatalytic oxide properties and flexible plastic properties. Processing cost is low and it does not require any expensive equipment investment. Processing can be scalable to current manufacturing infrastructure.

Cho, Junghyun↗

DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗

DOE OSTI2018

Aluminum Ion Beam Treatment of Zirconium Ceramics

The paper presents the radiation and thermal treatment of zirconium ceramics with high-energy Al ion beams generated at an accelerating voltage of 1.5 kV, which modifies the structure and electrophysical properties of zirconium ceramics. Compact powder and ceramic samples are used for the radiation and thermal treatment performed at 1123–1173 K. The surface treatment of compact powders leads to the increase in the grain size, whereas the surface of ceramic samples turns black and electrically conductive in depth. This is because the change in the oxygen stoichiometry of zirconium ceramics. Air annealing of treated ceramics returns the sample to the initial state. The phase composition, microhardness and density of ceramic samples display no changes after the radiation and thermal treatment. Under the experimental conditions, the diffusion of aluminum ions in the surface layer is not observed. It is found that the ion beam treatment leads to the decrease in aluminum-containing impurity in the surface layers of zirconium ceramics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2019

A review of computational modeling techniques in study and design of shape memory ceramics

Shape memory ceramics are a unique family of shape memory materials with a wide variety of applications, such as ultra-high energy dissipation and high-temperature actuation. Along with significant progress in the experimental study of zirconia-based shape memory ceramics in recent years, computational simulations have exhibited powerful capabilities in revealing nano/microstructure-dependent deformation and failure mechanisms in these materials. In this work, we review the recent progress in understanding the phase transformation behavior in shape memory ceramics, focusing on computational modeling of zirconia-based ceramics. Electronic structure calculations have provided new data on the phase stability and surface properties of shape memory ceramics. At the nanometer length scale, molecular dynamics simulations have captured fundamental information about martensitic phase transformation and the effects of grain boundaries and defects on mechanical response of bi- and polycrystalline zirconia-based ceramics. At the micrometer length scale, advanced phase-field models have shown the ability to predict morphological evolution of microstructures and the corresponding mechanical responses in good agreement with experimental observations. Despite the recent multiscale computational advancements, further developments are required to establish processing-structure-property-performance relations that will lead to reliable and practical strategies for designing zirconia-based (or other) ceramics with improved and sustained shape memory responses. This article critically reviews current computational modeling techniques and provides an outlook for the study and design of the next generation of shape memory ceramics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Fusion welding of refractory metals and ZrB 2 -SiC-ZrC ceramics

Molybdenum and a molybdenum alloy were fusion welded to ZrB2-based ceramics to determine if the electrical and thermal properties of the metals and ceramics affected their weldability. Commercial ceramic powders were hot pressed, machined into coupons, and preheated to 1600 °C before joining the ceramics to commercial metals using plasma arc welding. Weldability varied as indicated by the range of porosity observed within the fusion zones. Measured thermal and electrical properties appeared to have little to no effect on the weldability of metal-ceramic welds despite the large range of values measured across each property. Differences in melting temperatures between metal and ceramic coupons did affect weldability by changing the weld penetration depth into ceramic coupons. Finally, future studies on metal-ceramic welds are suggested to investigate the effect that work function, melt viscosity, wetting, or other properties have on weldability.

36 MATERIALS SCIENCE↗

DOE OSTI2018

High energy storage properties of (Ni1/3Nb2/3)4+ complex-ion modified (Ba0.85Ca0.15)(Zr0.10Ti0.90)O3 ceramics

Highlights: • BCZT-xNN ceramics showed single phase perovskite structure without an obvious second phase after adding NN, and exhibited both good temperature (−55 to 160 °C) and frequency (10{sup 2}–10{sup 7} Hz) stability. • The highest energy storage density can reach 0.66 J/cm{sup 3} and the energy efficiency is 88.1% was achieved in x = 0.3. • The environmental friendly (lead-free) BCZT-xNN ceramics are good candidate for application in energy storage devices. • This paper also developes a new method to obtain high energy storage density and efficiency of ceramic capacitor, which aims to adjust the T{sub c} of ceramics far below room temperature. - Abstract: In this study, paraelectric ceramics, (Ba{sub 0.85}Ca{sub 0.15})(Zr{sub 0.10}Ti{sub 0.90}){sub 1-x}(Ni{sub 1/3}Nb{sub 2/3}){sub x}O{sub 3,} abbreviated as BCZT-xNN (with x = 0.1, 0.2, 0.3, 0.4) were prepared via a solid-state reaction method. By introducing a B-site complex-ion, (Ni{sub 1/3}Nb{sub 2/3}){sup 4+}, the Curie temperature of the ceramic could be reduced to below room temperature. The effects of this B-site (Ni{sub 1/3}Nb{sub 2/3}){sup 4+} complex-ion substitution on the phase structure, surface microstructure as well as the dielectric, ferroelectric, and energy storage properties of the ceramic were systematically investigated. After adding NN, BCZT-xNN shows a single phase perovskite structure without evidence of a second phase . In addition, we observed high stability with respect to both temperature (−55 to 160 °C) and frequency (10{sup 2}–10{sup 7} Hz). Doping with NN produces slim polarization-electric field hysteresis loops and enhanced energy storage properties, while the efficiency decreases. When x = 0.3, the highest energy storage density reached 0.66 J/cm{sup 3} for a high electric field (20 kV/mm), and the respective energy efficiency was 88.1%. These properties indicate that the environmental friendly BCZT-xNN ceramics are promising candidates for commercial energy storage devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

The effect of Gd3+ ions on fabrication and luminescence properties of Nd3+-doped (Ca1-xGdx)F2+x transparent ceramics

Highlights: • Nd:(Ca{sub 1-x}Gd{sub x})F{sub 2+x} transparent ceramics were fabricated by hot-pressing method. • Concentration effect of Gd{sup 3+} ion on the optical properties are discussed. • The emission properties have been greatly enhanced by codoping with Gd{sup 3+}ions. • The fluorescence parameters were compared to other Nd{sup 3+}-doped optical materials. - Abstract: Nd:(Ca{sub 1-x}Gd{sub x})F{sub 2+x} (x = 0.01–0.1) transparent ceramics were fabricated by hot-pressing the co-precipitated synthetic nanopowders in vacuum. The as-fabricated Nd:(Ca{sub 1-x}Gd{sub x})F{sub 2+x} transparent ceramics exhibit nearly pore-free and uniform microstructure, the in-line transmittance of all samples is beyond 86% at 1064 nm. The effect of Gd{sup 3+} ions on the transparency and grain size of Nd:(Ca{sub 1-x}Gd{sub x})F{sub 2+x} transparent ceramics has been demonstrated. The dependence of emission intensity and lifetime on Gd{sup 3+} concentration for Nd:(Ca{sub 1-x}Gd{sub x})F{sub 2+x} transparent ceramics is investigated and discussed. The introducing of Gd{sup 3+} is found to increase emission intensity and lifetime dramatically. The fitting results of fluorescence decay curves show the lifetime of 1 at.% Nd:(Ca{sub 0.9}Gd{sub 0.1})F{sub 2.1} transparent ceramic is to be 373.80 μs which is greatly larger than that of 1 at.% Nd:CaF{sub 2} transparent ceramic. The spectroscopic parameters of Nd:(Ca{sub 1-x}Gd{sub x})F{sub 2+x} transparent ceramics and other Nd{sup 3+}-doped optical materials have been compared and discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

Novel ceramic capacitors with ultrahigh energy density and efficiency (Final Technical Report)

Antiferroelectric ceramics are a special class of material that have shown great potential as the dielectric in electrical capacitors due to their high energy- and power-density. During each charge-discharge cycle, the ceramic undergoes transformation to a ferroelectric phase and resumes its antiferroelectric phase. The hysteresis associated with the transitions leads to a mediocre energy efficiency and service lifetime of antiferroelectric capacitors and, hence, their almost absence in commercial products. Under the support of this research project, we first formulated a universal lattice-compatibility theory that included electrostatic polarization energy along with elastic energy and thermal energy to understand the origin of the hysteresis in antiferroelectric oxides. Guided by this compatibility theory, we conducted high-throughput density functional theory (DFT) calculations to assess chemical modifiers and their effect on crystal structures of 400+ PbZrO 3 -based compositions. Down-selected compositions were experimentally validated for their suppressed hysteresis and higher energy efficiency. The verified low-hysteresis compositions were then expanded to an antiferroelectric ceramic library with nearly 500 new compositions (more than 1,500 samples) using high-throughput experiments involving ceramic synthesis and property screening. The large quantity of data generated (theory and experimental) in these tasks were processed by machine-learning techniques and identified trends were fed to the next iteration. In the end, we successfully discovered four compositions with near-zero hysteresis, yielding a world-record energy efficiency of 98.2% at an energy density of 3.0 J/cm 3 . Furthermore, our antiferroelectric ceramic capacitor reaches 79.5 million charge-discharge cycles lifetime, a factor of 80 enhancement over previous antiferroelectric ceramics with large hysteresis. These research accomplishments have not only met the milestones set in the SOPO, but also led to two patent filings, three journal publications (one of them was in Advanced Materials, impact factor 29.4), and nine oral presentations at various venues. Through the course of the project, three postdocs, four Ph.D. students, and one M.S. student were trained. In short, our project established a new methodology in searching next-generation functional ceramics on the fundamental side and discovered several high-efficiency antiferroelectric compositions for capacitors on the applied side. Once fabricated into the multilayer form for commercial applications, these ceramic capacitors can potentially enable the high temperature high power density DC-link capacitors that are critical for the next generation inverters in electric vehicles. The project also significantly contributed to the nation’s workforce development in the STEM fields.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Green micromachining of ceramics using tungsten carbide micro-endmills

This paper presents an experimental analysis on micromachining of green-state silicon carbide (SiC) and aluminum nitride (AlN) using uncoated tungsten carbide (WC) micro-endmills. Although the unique properties of ceramics make them ideal materials for many applications involving micro-scale features, the industrial adaptation of ceramics at the micro-scale has been hindered due to the lack of viable ceramic micro-manufacturing techniques. Green micromachining (GMM), where micro-scale features are created by micromachining green-state ceramics that contain ceramic particles and a polymer binder, offers a potential solution for this problem by affording tremendous improvements in micromachinability with respect to sintered ceramics. After the completion of GMM, the green parts are debound and sintered to obtain the final component with the desired microscale features. In this work, we evaluated GMM characteristics of powder-injection molded green-state SiC and AlN to correlate process conditions and green-material compositions with the micromachining forces, quality, and tool wear. An experimental study that involves full immersion micromilling tests with 254 μm diameter micro-endmills at different cutting speeds and feed rates is conducted. For each of the two materials, two binder states (with and without wax) and two powder states (with micro particles only, or with both micro- and nanoparticles) are investigated. Green micromachining forces, specific energies and the resulting surface roughness are analyzed quantitatively. A qualitative analysis of burr formation and channel quality, as well as a preliminary study on micro-tool wear are also performed. Both the machining conditions and the material compositions are seen to have a strong effect on micro-machinability of green-state ceramics. Overall, we conclude that GMM can be a viable ceramic micro-manufacturing strategy if favorable (or optimal) micromachining and material parameters are identified through the presented (or a similar) micromachinability study.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Prototype Ceramic High Efficiency Particulate Air Filter Testing and Filter Media Development for Nuclear Facility Ventilation

This report summarizes recent and past related Ceramic HEPA Filter activity for this NNSA NSR&D project and on-going plans for FY18 and FY19 work as presently planned. Prior work has evaluated concepts for a ceramic HEPA filter including ceramic support materials, filter media including electrospun filter media, and metal housing designs to accommodate the conservative temperature performance target of up to 500°C. This has been supported by modelling efforts discussed with nuclear facility system engineers and their management. The temperature and time-at-temperature are based on conservative, bounding temperatures from fire analysis presented as a draft EFCOG best practice paper for nuclear facility safety analysis. The overall goal is to improve safety of DOE nuclear facilities during fire scenarios by developing improved filtration technology including increasing performance while reducing pressure drop. Ceramic filtration technology can provide robust, passive mitigation against radiological releases. The goal of the ceramic HEPA filter is to provide a robust HEPA filter that provides increased temperature performance in an equivalent form factor (size and shape) that is similar to existing conventional HEPA filters used in facilities. Once qualified for use in facilities, the benefit of a ceramic HEPA filters could simplify and reduce safety and support system costs, as well as considerably lower life-cycle costs. Installation, monitoring, and maintenance of active fire suppression systems, as well as other related systems, are a considerable on-going cost to nuclear facilities. Reducing the level of dependence on Safety Class and Safety Significant fire alarm and fire suppression systems could allow significant cost savings. At present we are continuing research and development efforts towards the goal of a ceramic filter design, including improved ceramic filter media, that could reduce total operation cost for facilities utilizing HEPA filters.

42 ENGINEERING↗

DOE OSTI2019

Prototype Ceramic HEPA Filter Testing and Filter Media Research and Development for Nuclear Facility Ventilation

This is a brief summary of recent and past Ceramic HEPA Filter research and development activities under an NNSA NSR&D funded project and describes on-going plans for FY19 work as presently planned. Prior work has evaluated concepts for a ceramic HEPA filter including ceramic support materials, filter media including electrospun filter media, and metal housing designs to accommodate the conservative temperature performance target of up to 500°C. This has been supported by modelling efforts discussed with nuclear facility system engineers and their management. The temperature and time-attemperature are based on conservative, bounding temperatures from fire analysis presented as an EFCOG best practice paper for nuclear facility safety analysis. The overall goal is to improve safety of DOE nuclear facilities during fire scenarios by developing improved filtration technology including increasing temperature performance while maintaining acceptable filter pressure drop. Ceramic filtration technology can provide robust, passive mitigation against radiological releases. The goal of the ceramic HEPA filter is to provide a HEPA filter that provides increased temperature performance in an equivalent form factor (size and shape) that is similar to existing conventional HEPA filters used in facilities. Once development is complete and qualified for use in facilities, ceramic HEPA filters could simplify and reduce safety and support system costs, as well as lower life-cycle costs. Installation, monitoring, and maintenance of active fire suppression systems, as well as other related systems, are a considerable on-going cost to nuclear facilities. Reducing the level of dependence on Safety Class and Safety Significant fire alarm and fire suppression systems could allow significant cost savings. At present we are continuing research and development efforts towards the goal of a ceramic filter design, including improved ceramic filter media, that could reduce total operation cost for facilities utilizing HEPA filters.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Prototype Ceramic HEPA Filter Testing and Filter Media Research and Development for Nuclear Facility Ventilation

This is a brief summary of recent and past Ceramic HEPA Filter research and development activities under an NNSA NSR&D funded project and describes on-going plans for FY19 work as presently planned. Prior work has evaluated concepts for a ceramic HEPA filter including ceramic support materials, filter media including electrospun filter media, and metal housing designs to accommodate the conservative temperature performance target of up to 500°C. This has been supported by modelling efforts discussed with nuclear facility system engineers and their management. The temperature and time-at-temperature are based on conservative, bounding temperatures from fire analysis presented as an EFCOG best practice paper for nuclear facility safety analysis. The overall goal is to improve safety of DOE nuclear facilities during fire scenarios by developing improved filtration technology including increasing temperature performance while maintaining acceptable filter pressure drop. Ceramic filtration technology can provide robust, passive mitigation against radiological releases. The goal of the ceramic HEPA filter is to provide a HEPA filter that provides increased temperature performance in an equivalent form factor (size and shape) that is similar to existing conventional HEPA filters used in facilities. Once development is complete and qualified for use in facilities, ceramic HEPA filters could simplify and reduce safety and support system costs, as well as lower life-cycle costs. Installation, monitoring, and maintenance of active fire suppression systems, as well as other related systems, are a considerable on-going cost to nuclear facilities. Reducing the level of dependence on Safety Class and Safety Significant fire alarm and fire suppression systems could allow significant cost savings, while maintaining safety. At present we are continuing research and development efforts towards the goal of a ceramic filter design, including improved ceramic filter media, that could reduce total operation cost for facilities utilizing HEPA filters.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Development of large-scale, 3D Printed high temperature ceramic material

Through this collaborative effort, a new 3D printing platform for ceramics called laser-induced slip casting (LIS) was explored and developed for improving the processing and manufacture of silicon carbide (SiC), a high temperature ceramic material. This method prints layers of ceramic slips/slurries with subsequent selective-laser heating to dry each layer to build a 3D structure. The completed and dried part is then sintered. This manufacturing process is inherently lower cost than alternative ceramic printing methods such as binder jet technology or stereolithography when it comes to the feedstock material but is more expensive than robocasting or direct ink writing. However, it has the potential to make more controlled parts with less defects compared to robocasting. The largest cost is the heating source for the printer. With this technique, there is potential to make large ceramic parts in a near-net shape. Further, there is no known commercial manufacturing of 3D printed ceramics that creates a large range of different high-density ceramics at large scale. The goals and outcomes for the development of the new printing technology were: 1) assessing the technology with alumina by characterizing coupons, 2) printing and sintering of silicon carbide (SiC), and 3) characterization and properties testing of materials printed and a scale-up of SiC part(s). Through this collaborative project, it was sought to provide the best solution to achieving highly dense and near-net shaped ceramic parts at large scale and reduced cost. The goal was to produce high density sintered materials for applications in defense, energy generating systems, armor, and wear parts using 3D printing methods. Variables including powder particle sizes, dispersant molecular weights (MWs), binders, printing parameters, and post processing were explored as well as the characterization of the physical properties (add specifics here).

36 MATERIALS SCIENCE↗

NASA NTRS1983

Correlation of compressive stress with spalling of plasma sprayed ceramic materials

Ceramics on metal substrates for potential use as high temperature seals or other applications are exposed to forces originating from differences in thermal expansion between the ceramic and the metal substrate. This report develops a relationship between the difference in expansion of the ceramic and the substrate, defines conditions under which shear between the ceramic and the substrate occurs, and those under which bending forces are produced in the ceramic. The off-axis effect of compression forces resulting from high temperature plastic flow of the ceramic producing buckling of the ceramic is developed. Shear is associated with the edge or boundary stresses on the component while bending is associated with the distortion of an interior region. Both modes are significant in predicting life of the ceramic.

Mullen, R. L.↗

NASA NTRS1981

Ceramic applications in turbine engines

Development testing activities on the 1900 F-configuration ceramic parts were completed, 2070 F-configuration ceramic component rig and engine testing was initiated, and the conceptual design for the 2265 F-configuration engine was identified. Fabrication of the 2070 F-configuration ceramic parts continued, along with burner rig development testing of the 2070 F-configuration metal combustor in preparation for 1132 C (2070 F) qualification test conditions. Shakedown testing of the hot engine simulator (HES) rig was also completed in preparation for testing of a spin rig-qualified ceramic-bladed rotor assembly at 1132 C (2070 F) test conditions. Concurrently, ceramics from new sources and alternate materials continued to be evaluated, and fabrication of 2070 F-configuration ceramic component from these new sources continued. Cold spin testing of the critical 2070 F-configuration blade continued in the spin test rig to qualify a set of ceramic blades at 117% engine speed for the gasifier turbine rotor. Rig testing of the ceramic-bladed gasifier turbine rotor assembly at 108% engine speed was also performed, which resulted in the failure of one blade. The new three-piece hot seal with the nickel oxide/calcium fluoride wearface composition was qualified in the regenerator rig and introduced to engine operation wiwth marginal success.

Byrd, J. A.↗

NASA NTRS1983

Correlation of compressive and shear stress with spalling of plasma-sprayed ceramic materials

Mullen, R. L.↗