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NASA NTRS2016

Experimentally Observed Electrical Durability of 4H-SiC JFET ICs Operating from 500 C to 700 C

Prolonged 500 degrees Celsius to 700 degrees Celsius electrical testing data from 4H-SiC junction field effect transistor (JFET) integrated circuits (ICs) are combined with post-testing microscopic studies in order to gain more comprehensive understanding of the durability limits of the present version of NASA Glenn's extreme temperature microelectronics technology. The results of this study support the hypothesis that T ≥ 500 degrees Celsius durability-limiting IC failure initiates with thermal-stress-related crack formation where dielectric passivation layers overcoat micron-scale vertical features including patterned metal traces.

high temperature↗

DOE OSTI2021

Evaluation of Low-Pressure-Sintered Multi-Layer Substrates for Medium-Voltage SiC Power Modules: Preprint

Direct-bonded aluminum (DBA) multi-layer substrates have been fabricated using low-pressure silver sintering. These multi-layer substrates can be used to reduce the peak electric field strength inside power modules. This benefit is particularly important for medium-voltage silicon carbide (SiC) MOSFETs due to their higher operating voltages. The voiding content and defect density of the bond used to create the multi-layer substrate stackup is critical to the thermal performance and reliability of the power module. This work two low-pressure-assisted sintering techniques; one using nano-silver preform and the other using nano-silver paste to bond 23 mm by 49 mm DBA substrates. Scanning acoustic microscopy (C-SAM) is used to evaluate the bond quality after sintering. To evaluate the reliability of the sintered multi-layer substrates, passive thermal cycling from –40 °C to 200 °C was performed. Cross-sections were cut at pre-determined intervals and imaged with Scanning Electron Microscopy (SEM). After 1,000 thermal cycles, minor cracking was observed, but no failures have occurred.

28 EE - Advanced Manufacturing Office (EE-5A)↗

NASA NTRS2019

Uniaxial Tensile Properties of AS4 3D Woven Composites with Four Different Resin Systems: Experimental Results and Analysis: Property Computations

As a part of the NASA Composite Technology for Exploration project, eight different AS4 3D orthogonal woven composite panels were manufactured and were subjected to mechanical testing including uniaxial tension along the weaves' warp direction. Each set, with four different resin systems (KCR-IR6070, EP2400, RTM6, and RS-50), included weave architectures designed using 12K and 6K AS4 carbon fiber yarns. For the tension testing conducted at Room Temperature Ambient (RTA) conditions, the elastic modulus and strength of these eight panels (as-processed and thermally-cycled) were measured and compared while the potential evolution of micro-cracking before and after thermal cycling were monitored via optical microscopy and X-Ray Computed Tomography. The data set also included test results of the as-processed materials at Elevated Temperature Wet (ETW) conditions. In the second part of this study, efforts were made to compute elastic constants for AS4 6K/RTM6 and AS4 12K/RTM6 materials by implementing a finite element approach and the Multiscale Generalized Method of Cells (MSGMC) technique developed at NASA Glenn Research Center. Digimat-FE was used to model the weave architectures, assign properties, calculate yarn properties, create the finite element mesh, and compute the elastic properties by applying periodic boundary conditions to finite element models of each repeating unit cell. The required input data for MSGMC was generated using Matlab® from Digimat exported weave information. Experimental and computational results were compared, and the differences and limitations in correlating to the test data were briefly discussed.

Property Computations↗

NASA NTRS2019

Uniaxial Tensile Properties of AS4 3D Woven Composites with Four Different Resin Systems: Experimental Results & Analysis - Property Computations

As a part of the NASA Composite Technology for Exploration project, eight different AS4 3D orthogonal woven composite panels were manufactured and were subjected to mechanical testing including uniaxial tension along the weaves' warp direction. Each set, with four different resin systems (KCR-IR6070, EP2400, RTM6, and RS-50), included weave architectures designed using 12K and 6K AS4 carbon fiber yarns. For the tension testing conducted at Room Temperature Ambient (RTA) conditions, the elastic modulus and strength of these eight panels (as-processed and thermally cycled) were measured and compared while the potential evolution of micro-cracking before and after thermal cycling were monitored via optical microscopy and X-Ray Computed Tomography. The data set also included test results of the as-processed materials at Elevated Temperature Wet (ETW) conditions. In the second part of this study, efforts were made to compute elastic constants for AS4 6K/RTM6 and AS4 12K/RTM6 materials by implementing a finite element approach and the Multiscale Generalized Method of Cells (MSGMC) technique developed at NASA Glenn Research Center. Digimat-FE was used to model the weave architectures, assign properties, calculate yarn properties, create the finite element mesh, and compute the elastic properties by applying periodic boundary conditions to finite element models of each repeating unit cell. The required input data for MSGMC was generated using MatlabÂ® from Digimat exported weave information. Experimental and computational results were compared, and the differences and limitations in correlating to the test data were briefly discussed.

Property Computations↗

NASA NTRS1988

Cracking of a layered medium on an elastic foundation under thermal shock

The cladded pressure vessel under thermal shock conditions which is simulated by using two simpler models was studied. The first model (Model 1) assumes that, if the crack size is very small compared to the vessel thickness, the problem can be treated as a semi-infinite elastic medium bonded to a very thin layer of different material. However, if the crack size is of the same order as the vessel thickness, the curvature effects may not be negligible. In this case it is assumed that the relatively thin walled hollow cylinder with cladding can be treated as a composite beam on an elastic foundation (Model 2). In both models, the effect of surface cooling rate is studied by assuming the temperature boundary condition to be a ramp function. The calculated results include the transient temperature, thermal stresses in the uncracked medium and stress intensity factors which are presented as a function of time, and the duration of cooling ramp. The stress intensity factors are also presented as a function of the size and the location of the crack. The problem is solved for two bonded materials of different thermal and mechanical properties. The mathematical formulation results in two singular integral equations which are solved numerically. The results are given for two material pairs, namely an austenitic steel layer welded on a ferritic steel substrate, and a ceramic coating on ferritic steel. In the case of the yielded clad, the stress intensity factors for a crack under the clad are determined by using a plastic strip model and are compared with elastic clad results.

Rizk, Abd El-Fattah A.↗

NASA NTRS1976

Influences of chemical and thermal environments on delay in a Ti-6Al-4V alloy

Experiments were conducted within the framework of linear fracture mechanics to study the effects of chemical and thermal environments on crack-growth retardation (delay) in mill-annealed Ti-6Al-4V alloy under elemental load spectra. Attention is focused on the influence of hold time at high load on delay in a 3.5 percent NaCl solution at room temperature. It is shown that delay is strongly affected by hold time at high load, where delay is longest if the high-load excursion occurs at high temperature and the subsequent fatigue is at room temperature, and shortest if the temperature profile is reversed. The results suggest that residual stresses ahead of the advancing crack play an important role in delay. The significance of combined load and environment (chemical and thermal) effects in terms of modeling and life prediction procedures is discussed.

Shih, T. T.↗

NASA NTRS2001

Thermal Fatigue and Fracture Behavior of Ceramic Thermal Barrier Coatings

Thermal fatigue and fracture behavior of plasma-sprayed ceramic thermal barrier coatings has been investigated under high heat flux and thermal cyclic conditions. The coating crack propagation is studied under laser heat flux cyclic thermal loading, and is correlated with dynamic fatigue and strength test results. The coating stress response and inelasticity, fatigue and creep interactions, and interface damage mechanisms during dynamic thermal fatigue processes are emphasized.

Zhu, Dong-Ming↗

DOE OSTI2021

Evaluation of ceria as a surrogate material for UO 2 in experiments on fuel cracking driven by resistive heating

A variety of normal operation and accident scenarios can generate thermal stresses large enough to cause cracking in light-water reactor (LWR) fuel pellets. Cracking of fuel pellets can lead to reduced heat removal, larger centerline temperatures, and localized stress in cladding all of which impact fuel performance. Furthermore, pellet cracking also contributes to a temperature reduction in the pellet since the pellet fragments tend to move towards the heat sink (cladding), and the heat flow remains predominantly radial despite the presence of cracks. It is important to understand the temperature profile on the pellet before and after cracking to improve cracking models in fuel performance codes However, in-reactor observation and measurement of cracking is very challenging owing to the harsh environment and design of fuel rods. Recently, an experimental pellet cracking test stand was developed for separate effects testing of normal operations and accident temperature conditions, using thermal imaging to capture the pellet surface temperature for evaluation of thermal stresses and optical imaging to capture the evolution of cracking in real time. Cracking experiments were initially performed using ceria (CeO 2 ) as a surrogate fuel material, which is useful for developing and demonstrating the experimental approaches but is also valuable in its own right for cracking model development and validation. A combination of induction and resistance heating was used for volumetric heat generation in the pellet creating a thermal gradient. The material properties of CeO 2 and UO 2 are reviewed and compared for use in model development. Simulations of the experiment were performed to evaluate the behavior of the surrogate (CeO 2 ) fuel in BISON. The measured temperature profiles from BISON models match reasonably well with the observed experiments for the ceria pellets before cracking. The findings from this work will help improve confidence in fracture models used for fuel pellets under similar in-reactor conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Separate-Effects Tests for Studying Temperature-Gradient-Driven Cracking in UO 2 Pellets

We report a variety of normal operation and accident scenarios can generate thermal stresses large enough to cause cracking in light-water reactor (LWR) fuel pellets. Cracking of fuel pellets can lead to reduced heat removal, higher centerline temperatures, and localized stress in cladding, all of which impact fuel performance. It is important to experimentally characterize the thermal and mechanical behavior in the pellet before and after cracking to improve cracking models in fuel performance codes. However, in-reactor observation and measurement of cracking is very challenging due to the harsh environment and logistics. Recently, an experimental pellet cracking test stand was developed for separate effects testing of normal operations and accident temperature conditions, using thermal imaging to capture the pellet surface temperature for evaluation of thermal stresses and optical imaging to capture the evolution of cracking in real time. Experiments were performed using depleted uranium dioxide (UO 2 ) pellets, which are useful for collecting data valuable for development and validation of cracking models. A combination of induction and resistance heating was used to create an average temperature gradient of 236°C/cm and 193°C/cm before and after cracking respectively. Characterization of the pellets were done before as well as after cracking. The cracking patterns are somewhat different than those expected in a typical reactor because of the differences in thermal conditions and pellet microstructure. However, if the actual conditions of these experiments are reproduced in computational models, these out-of-pile tests on UO 2 pellets provide relevant data for modeling purposes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1974

Model for thermal stress resistance of truly elastic materials containing more than one crack

The model was developed upon the physical properties of surface energy and intrinsic modulus of elasticity of a material containing a number of equal sized microcracks which are independent of one another. The effect of these cracks upon the strain energy per unit volume of material necessary to continue simultaneous crack growth as well as the measured physical properties was established, and the thermal stress resistance is developed in terms of this energy. The model is expressed in its final form in terms of the measured physical properties of fracture strength, effective modulus of elasticity, and coefficient of thermal expansion. The model was applied to existent thermal stress data of ceramic materials for which these physical properties had been measured. On the basis of these data it was concluded that the thermal stress resistance of a material may be improved by increasing the fracture strength.

Lineback, L. D.↗

NASA NTRS1995

Preventing Cracking of Anodized Coatings

Anodized coatings have been used as optical and thermal surfaces in spacecraft. Particulate contamination from cracked coatings is a concern for many applications. The major cause for the cracking is the difference in the coefficient of thermal expansion between the oxide coatings and the aluminum substrate. The loss of water when the coating is exposed to a vacuum also could induce cracking of the coating. Hot-water sealing was identified as the major cause for the cracking of the coatings because of the large temperature change when the parts were immersed in boiling water and the water was absorbed in the coating. when the hot-water sealing process was eliminated, the cracking resistance of the anodized coatings was greatly improved. Also, it was found that dyed black coatings were more susceptible than clear coatings to cracking during thermo-vacuum cyclings.

He, Charles C.↗

DOE OSTI2021

Healing of nanocracks by collision cascades in nickel

We use molecular dynamics simulations to investigate the interaction between collision cascades and pre-existing nano-cracks in nickel (Ni). We find that collision cascades cause the cracks to heal whenever a cascade initiates a thermal spike whose core overlaps with the crack. Moreover, crack healing affects the distribution of radiation-induced defects generated during a collision cascade: defect clusters, such as dislocations and stacking fault tetrahedra, dominate in the presence of crack healing, while isolated point defects dominate in its absence. Furthermore, this work indicates that irradiation may reduce the number of pre-existing crack-like flaws in metallic components, potentially improving their mechanical resilience.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Failure analysis of plasma-sprayed thermal barrier coatings

Thermally induced failure processes of plasma-sprayed thermal barrier coatings are examined. Cracking processes give rise to noise which was monitored by acoustic emission (AE) techniques. The sequential failure of coatings was examined from samples which were thermally cycled. Coatings of yttria-stabilized zirconia with and without a NiCrAlZr bond coat were plasma-sprayed onto U700 alloy rod. In some cases the substrate was intentionally overheated during deposition of the thermal protection system to check how this process variable influenced the AE response of the specimen. In this way a qualitative appraisal of how process variables affect coating integrity could be discerned in terms of cracking behavior. Results from up to seven consecutive thermal cycles are reported here. Coating failure was observed in all cases. Failure of the thermal protection system is progressive, since cracking and crack growth were observed prior to ultimate failure. Thus castastrophic failure occurs at some stage when there is a transformation from the microcrack to a macrocrack network.

Berndt, C. C.↗

NASA NTRS1984

Failure analysis of plasma-sprayed thermal barrier coatings

Berndt, C. C.↗

NASA NTRS1993

Advanced reinforcement systems for intermetallic applications

A 2-D axisymmetric model was employed to determine the magnitude of the radial, axial, and hoop stresses caused by the thermal expansion difference between fiber and matrix and which result from the fabrication temperature cycle. Finite element analysis was conducted for single fiber model systems based on SCS-6/Ti3Al+Nb and Al2O3/NiAl. The stress distribution due to the imposition of a graded intermediate layer for each system was determined and included variables of layer thickness and gradation in interlayer chemistry in order to vary the expansion gradient between fiber and matrix. Thermal cycling tests were conducted on sputter coated SCS-6 fibers selectively coated with Ti3Al+Nb, with and without an intermediate layer. Cracking of the Ti3Al+Nb layers was prevented by an interlayer based on Ti-TiN-Ti. The interlayer thickness appeared critical to its efficiency. Similarly, for the case of Al2O3/NiAl, an intermediate layer consisting of a Ni bond coat on the sapphire fiber followed by a graded Al2O3-NiAl layer did not crack when given a thermal excursion to 1100 C and then cooled to room temperature. Acoustic emission tests on single fiber specimens were unsuccessful in detecting load drops associated with the successive fracture of the fiber. For the SCS-6/Ti3Al system this was the result of several factors which included the matrix/fiber ratio and poor bonding of the matrix and fiber. In the case of the Al2O3/NiAl system brittle failure of the NiAl matrix precluded fiber breakdown during tensile loading.

Merrick, Howard F.↗

DOE OSTI2023

Highly-Conductive and Durable SOFC Cathode-Side Contact Based on Reactively-Sintered Mn-Co Spinel

A cathode-side contact layer with well-matched coefficient of thermal expansion is needed to prevent cracking of solid oxide fuel cell stacks from thermal cycling during stack operations. An Mn 1.25 Co 1.75 O 4 (MCO) spinel layer synthesized via reactive sintering with a metal-containing precursor was proposed as a highly conductive and durable contact material. Compared to the interconnect/contact/cathode assemblies with the (La 0.80 Sr 0.20 ) 0.95 MnO 3-x and La(Mn 0.45 Co 0.35 Cu 0.2 )O 3 contacts, the assembly with the MCO contact exhibited the lowest area-specific resistance at 800 °C (8.2 mΩ·cm 2 ) during 2000-h cyclic exposure and was crack-free based on the cross-sectional examination, indicative of the superiority of the spinel contact over the perovskite counterparts.

Electrochemistry↗

NASA NTRS1991

Slow crack growth in glass in combined mode I and mode II loading

Slow crack growth in soda-lime glass under combined mode I and mode II loading was investigated in precracked disk specimens in which pure mode I, pure mode II, and various combinations of mode I and mode II were achieved by loading in diametral compression at selected angles with respect to symmetric radial cracks. It is shown that slow crack growth under these conditions can be described by a simple exponential relationship with elastic strain energy release rate as the effective crack-driving force parameter. It is possible to interpret this equation in terms of theoretical models that treat subcritical crack growth as a thermally activated bond-rupture process with an activation energy dependent on the environment, and the elastic energy release rate as the crack-driving force parameter.

Shetty, D. K.↗

NASA NTRS1980

Identification and analysis of factors affecting thermal shock resistance of ceramic materials in solar receivers

An analysis was conducted of the possible modes of thermal stress failure of brittle ceramics for potential use in point-focussing solar receivers. The pertinent materials properties which control thermal stress resistance were identified for conditions of steady-state and transient heat flow, convective and radiative heat transfer, thermal buckling and thermal fatigue as well as catastrophic crack propagation. Selection rules for materials with optimum thermal stress resistance for a particular thermal environment were identified. Recommendations for materials for particular components were made. The general requirements for a thermal shock testing program quantitatively meaningful for point-focussing solar receivers were outlined. Recommendations for follow-on theoretical analyses were made.

Hasselman, D. P. H.↗